4-Cylinder Diesel Engine (2 0 L Engine Common Rail Generation II)

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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2013 Volkswagen AG, Wolfsburg D3E8043AD3C

CC 2012 ➤ , Golf Cabriolet 2012 ➤
4-cylinder diesel engine (2.0 l engine, common rail, generation II) - Edition 09.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . .wa.g.en. A.G.. V.o.lk.sw.a.ge.n.AG. d. o.e . . . . . . . . . . . . . . . . . . . . 1

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1 Identification . . . . . . . . . . . . .d b. y.V. . . . . . . . . . . . . . . . . . . . . . . .t .gu.a.r . . . . . . . . . . . .
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1.1 Engine number/engine data tho . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o. . . . . . . . .
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2 Safety instructions . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . .
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2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.2 Safety precautions during road tests in which testing and measuring equipment is used . . 3
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2.3 Safety precautions when working on vehicles with a Start/Stop system . . . . . . . . . . . . . . 4
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2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.2 Foreign objects in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Testing vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.3 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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2.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3 engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Removing and installing ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.5 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.6 Assembly overview - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.7 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.8 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Contents i
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.3 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.1 Assembly overview – toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.3 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.2 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.4 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1 Sump, oil pump . . . . . . . . . G. ..V.o.lk.sw. a. g.e.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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1.1 Assembly overviewo-lksump swa / oil pump . . . .do. e.s.no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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1.2 Removing andsedinstalling
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1.3 Removingutand ho installing oil level and oil temperature sender or ...................... 160
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1.4 Removing ss and installing oil pump . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . 161
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1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

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2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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3.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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3.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

3.3 Removing and installing oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.4 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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4.2 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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2.3 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
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2.4 Electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

2.5 Removing and installing coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
ii Contents
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

3.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.1 Assembly overview - radiator/radiator
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
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1.3 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
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2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
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2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.3 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
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2.4 Removing and installing charge pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
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2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
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1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
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1.2 Filling, bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
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1.3 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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2 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

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2.1 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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2.3 Testing jammed-open injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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2.4 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
AG.
2.5 Removing and installing high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . 260

2.6 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.1 Checking fuel pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.2 Removing and installing fuel pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.3 Removing and installing fuel pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.4 Removing and installing air mass meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.5 Removing and installing differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
5.1 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
6 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
6.1 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
6.2 Testing vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
7 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
7.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
7.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
8 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
8.3 Removing and installing throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Contents iii
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

9.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.2 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
1.3 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
2.1 Assembly overview – emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3 SCR system (selective catalytic reduction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3.1 Assembly overview - tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3.2 Emptying tank for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3.3 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.4 Assembly overview - delivery module for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.5 Removing and installing heater element (heater cup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.6 Assembly overview - reducing agent delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3.7 Removing and installing reducing agent delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.8 Removing and installing injector for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
4 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 337
4.2 Removing and installing parts of exhaust gas temperature regulation . . . . . . . . . . . . . . . . 338
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
5.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
5.2 Checking changeover for exhaustsw gas AG. Volkswagen AG d
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5.3 Removing and installing exhaust db
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5.4 Checking exhaust gas recirculation
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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

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1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

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1.2 Removing and installing automatic glow period control unit . . . . . . . . . . . . . . . . . . . . . . . . 357
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1.3 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

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1.4 Removing and installing engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

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iv Contents
00 – Technical data
1 Identification
(VRL006124; Edition 09.2013)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

⇒ “1.1.1 Engine number”, page 1
⇒ “1.1.2 Engine data”, page 1
1.1.1 Engine number

The first 3 characters of the four-character engine code refer to
the mechanical configuration of the engine. They are stamped
onto the engine as before. The fourth digit denotes the power
output of the engine and depends on the engine control unit. The
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four digit engine code can be found on the identificationy Vplate,
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The engine number (“engine code” and “serialsa
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found at the joint between engine and gearbox -arrow-.
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code” and “serial number”.
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The engine code can also be found on the vehicle data sticker.
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The engine number consists of up to nine characters (alphanu‐
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meric). The first part (maximum 4 characters) makes up the
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“engine code”, and the second part (6 characters), the “serial
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number”. If more than 999,999 engines were produced with the
same code letters, the first of the six digits is replaced by a letter.
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1.1.2 Engine data
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Engine code CFHC CFFA CFFB CFGB CFGC CLLA
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Golf Cabrio 2011 ► 11.11 ►

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CC 2012 ► 02.12 ► 02.12 ► 02.12 ► 12.12 ► 02.12 ►
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Emissions fulfil EU 5 plus EU 5 EU 4

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Capacity l 2.0 2.0 2.0 2.0 2.0 2.0

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Output kW at rpm 103/4,000 100/4,200 103/4,200 125/4,200 130/4,200 125/4,200

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Torque Nm at rpm 320/ 320/ 320/ 350/ 380/ 350/ t. C rig
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1,500 … 2, 1,750 … 2, 1,750 … 2, 1,750 … 2, 1,750 ... 2, 1,750 … 2, pyri by
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500 500 500 500 500 500
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Bore ∅ mm 81.0 81.0 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4 4 4
Compression ratio 16.5 16.5 16.5 16.5 16.0 16.5
Fuel according to DIN EN DIN EN DIN EN DIN EN DIN EN
590 590 590 590 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module no yes yes yes yes yes
Catalytic converter yes yes yes yes yes yes
Exhaust gas recirculation yes yes yes yes yes yes
Turbocharging/supercharging yes yes yes yes yes yes
Charge air cooling yes yes yes yes yes yes
1. Identification 1
CC 2012 ➤ , Golf Cabriolet A2012
G. Volk➤
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4-cylinder diesel engine
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Engine code CFHC CFFA CFFB or a CFGB CFGC CLLA
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Particulate filter yes yes yes yes yes no 1)
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1) Particulate reduction system instead of particulate filter
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2 Rep. gr.00 - Technical data

2 Safety instructions agen

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⇒ “2.1 Safety precautions whenedworking
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⇒ “2.2 Safety precautions
s during road tests in which testing and
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measuring equipment is used”, page 3
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⇒ “2.3 Safety precautions when working on vehicles with a Start/
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Stop system”, page 4
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⇒ “2.4 Safety precautions when working on cooling system”, page
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⇒ “2.5 Safety precautions when working on the SCR system”,

page 4
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2.1 Safety precautions when working on
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fuel supply system
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The fuel line is under pressure.
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Risk of injury to eyes and skin from fuel.

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Wear eye protection and protective clothing to avoid eye inju‐

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ries and skin contact. Before loosening hose connections,

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wrap a cloth around the connection. Then release pressure by
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carefully opening the connection point.

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To prevent injuries to persons and destruction of the injection and by c lksw
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glow plug system, the following must be noted: Prote AG.
♦ Always switch off the ignition before connecting or discon‐

necting electrical wiring of injection and glow plug system or
connecting/disconnecting tester cables.
♦ Wash the engine only with the ignition switched off.
♦ Entries have been stored in the event memory of the engine
control unit if the engine was started after electrical connectors
had been disconnected: Read event memory in vehicle
self-diagnosis ⇒ Vehicle diagnostic tester .
Caution
♦ Observe required procedures when disconnecting battery

⇒ Electrical system; Rep. gr. 27 ; battery; Disconnecting
and reconnecting battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .
2.2 Safety precautions during road tests in

which testing and measuring equipment
is used
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
2. Safety instructions 3
♦ Operating from the front passenger seat may result in an ac‐

cident caused by releasing the front passenger air bag which
can cause injuries to the person sitting there.
2.3 Safety precautions when working on ve‐

hicles with a Start/Stop system
WARNING
Risk of injury from automatic start of engine on vehicles with

Start/Stop system.
♦ In the case of vehicles with activated Start/Stop system
(indicated by a message in the dash panel insert), it is
possible that the engine will start automatically when nec‐
essary.
♦ You must therefore ensure that the Start/Stop system is
deactivated when working on vehicle (switch ignition off,
switch ignition on again as required).
2.4 Safety precautions when ksw working on

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When the engine is warm, the cooling system is under pres‐

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Hot steam/hot coolant can escape - risk of scalding.

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Cover filler cap on expansion tank with a cloth and open care‐ h re
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Caution
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Danger of overheating due to incorrectly fitted cap.

♦ Tighten cap of coolant expansion tank until it engages.
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2.5 Safety precautions when working on the

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♦ The reduction agent can irritate skin, eyes and respiratory
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♦ After skin contact with this agent, wash immediately with
plenty of water.
♦ If necessary, call a doctor.

Caution
Protect separated electrical connections against wetting from

reduction agent by suitable means, e.g. plastic bag and cable
ties. Electrical connections may be damaged due to the high
penetration ability along with subsequent crystallisation of the
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Caution ss
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Immediately seal all openings and connections using suitable

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plugs to stop ingress of dirt. The smallest particle of dirt can
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cause extensive damage to the system.
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Make sure that no reduction agent gets onto the trim panels or
body components.
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If this occurs, wash out reduction agent using clear water and
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a lint-free cotton cloth.

If the reduction agent has already crystallised, use warm water
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Reduction agent that has not been removed will crystallise and
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damage the surface after some time.
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For information on storage and disposal see ⇒ Service net →
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Environment → Workshop disposal ! For country specific infor‐
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2. Safety instructions 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 Foreign objects in the engine”, page 6
⇒ “3.3 Testing vacuum system”, page 6
3.1 Rules for cleanliness
Caution
When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To avoid subsequent damage, the following n AG. Volkswagen AG do
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♦ Check air filter housing, air filter element and intake hoses
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♦ Check the whole charge air path and charge air cooler for
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If foreign objects are found in the charge air system, the charg‐
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When working on fuel supply and injection system, pay careful
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attention to the following rules of cleanliness:
♦ Before disconnecting, thoroughly clean all connections and
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adjacent areas e.g. with brake cleaner.
♦ Place removed parts on a clean surface and cover. Use only
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♦ Carefully cover opened components and connections or seal
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if repairs cannot be carried out immediately.
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♦ Install clean components only. Do not remove replacement

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♦ When the system is open: Do not work with compressed air.

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♦ Also ensure that no diesel fuel comes into contact with the
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coolant hoses. Should this occur, the hoses must be cleaned Prote
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immediately. Damaged hoses must be renewed.
3.2 Foreign objects in the engine
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
3.3 Testing vacuum system

All information on the vacuum system ⇒ page 284

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 7
⇒ “1.2 Separating engine and gearbox”, page 26
⇒ “1.3 Securing engine on engine and gearbox support”,
page 30
⇒ “1.4 Installing engine”, page 31
1.1 Removing engine

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Due to the enclosed spaces, observe the following during all
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♦ Route lines of any kind and cables so that original routing
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♦ Ensure that there is sufficient clearance to all moving or
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Special tools and workshop equipment required

♦ Workshop hoist - VAS 6100-
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at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Lifting tackle - 3033-
1. Removing and installing engine 7

Note
♦ Read anti-theft radio code as the next work step requires the
AG. Volkswagen
earth strap of the battery to be disconnected.
lksw
agen AG do
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♦ The engine is removed forwards together ris
ed b with the gearbox. ran
tee
tho or
♦ All cable ties which are opened ors cut through when the engine
au ac
is removed must be renewed/replaced in the same position
s
ce
when the engine is installed. e
nl
pt
du
an
itte
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erm
ab
– With ignition switched off, disconnect earth strap from battery.
ility
ot p
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
wit
, is n
connecting battery
h re
hole
spec
– Remove air filter housing with air mass meter and connecting
es, in part or in w
pipe ⇒ page 289 .
t to the co
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
rrectness of i
– Remove battery tray. In order to do so, unscrew the mounting
l purpos
screws -arrows-.
– Remove engine cover panel ⇒ page 7 .
nf
ercia
o
– Remove fuel filter ⇒ Fuel supply - diesel engines; Rep. gr.
rm
m
20 ; Fuel filter .
atio
om
n in
c
– Remove supplementary fuel pump - V393- or fuel pump 2 -

or
thi
e
V277- ⇒ Fuel supply system - diesel engines; Rep. gr. 20 ;

t
sd
iva
Fuel pump; Removing and installing fuel pump .
o
r
rp
cu
o
m
f
– Remove noise insulation ⇒ General body repairs, exterior;

en
ng
t.
yi Co
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐ Cop py
sulation . ht. rig
rig ht
py by
co Vo
– Drain coolant ⇒ page 189 .
by lksw
cted agen
Prote AG.
– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 00 ; Repair instructions; Drain‐
ing the refrigerant circuit .
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Removing and installing lock carrier .
– Unscrew bolt -arrow- and place filler neck for windscreen

washer system reservoir to one side.
– Remove coolant expansion tank and place on engine.
8 Rep. gr.10 - Removing and installing engine

– Unscrew bolt -arrow- (captivated nut), twist intake hose -A-

clockwise out of its bracket and remove it.
lkswage es n
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d ran
ir se tee
tho
or
– Pull off vacuum hoses -1- and -2-
au for charge air control. ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Separate connectors for exhaust temperature sender 1 -

G235- -1- for Lambda probe - G39- -3- and for exhaust tem‐
perature sender 4 - G648- -2-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
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o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect connector for exhaust temperature sender 3 -
G495- -1- (secured behind bracket).
– Guide lines out of brackets on plenum chamber bulkhead and
on turbocharger.
– Pull vacuum line off vacuum pump.

– Unscrew securing bolt for refrigerant line -arrow- on air con‐

ditioner compressor.
– Remove refrigerant line on air conditioner compressor and
place to one side without kinking.
– Disconnect quick-release couplings for heat exchanger

-arrows- on plenum chamber bulkhead.
lkswage es n
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byV ua
ed ran
– Unscrew positive cable -arrow-thfrom
or
is
starter at central electrics tee
and place cable on engine. s au or
ac
s ce
Vehicles with dual-clutch gearbox
le
un
pt
an
d
itte
– Remove gear-change mechanism from gearbox ⇒ Rep. gr.

y li
erm
ab
37 ; Gear-change mechanism; Assembly overview - Gear-
ility
ot p
change mechanism .
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– To release, turn catch of mechatronic connector -arrow- and

pull connector off.
Vehicles with manual gearbox
change mechanism .
– Remove tube-hose or plastic pipe from the clutch slave cylin‐
der ⇒ Rep. gr. 30 ; Clutch; Removing and installing
AG. Volkswlines
agen Afor
agen G do
clutch control mechanism . Volksw es n
ot g
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db ran
Continuation for all vehicles rise tee
tho or
au
– Remove wiper arms ⇒ Rep. gr. 92 ; Wind‐ Electrical
ss system; ac
screen wiper system; Removing and installing wiper arms .
ce
e
nl
pt
du
an
– Remove plenum chamber cover ⇒ General body repairs, ex‐
itte
y li
erm
terior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
ab
ility
installing plenum chamber cover .
ot p
wit
, is n
– Remove plenum chamber bulkhead ⇒ General body repairs,
h re
hole
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Assembly
spec
overview – plenum chamber bulkhead .
es, in part or in w
t to the co
– Remove engine control unit from its bracket ⇒ page 297 .
rrectness of i
– Release connector for engine wiring harness -arrow- and pull
it off the engine control unit.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Detach connectors -1- and-2- from left longitudinal member of
c by lksw
cted agen
vehicle. Prote AG.
– Unbolt earth cable on gearbox.

– Open locking mechanism -A- of aperture in plenum chamber
bulkhead.

– Pull out upper part upwards and remove engine wiring harness
from cable guide.
– Disconnect all connectors between starter, gearbox and body.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Unscrew securing bolt -arrow- on upper bracket of particulate
wit
, is n
filter and loosen securing bolt of bracket on cylinder head one
h re
turn.
hole
spec
es, in part or in w
– Disconnect connector on oil level and oil temperature sender
t to the co
- G266- .
– Remove drive shafts ⇒ Running gear, axles, steering; Rep.
rrectness of i
gr. 40 ; Drive shaft; Removing and installing drive shaft .
l purpos
nform
mercia
at
om
ion
c
– Unscrew bolts -1…3- and remove pendulum support.

in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Vehicles with auxiliary heater

AG. Volkswagen AG d
4-cylinder diesel engine sw agenl engine, common
(2.0 orail,
es n generation II) - Edition 09.2013
olk o t gu
yV
db ara
– Clamp off coolant hoses -1- hand
rise -2- with hose clips, up to nte
t o eo
25 mm in diameter - 3094-
s auand pull coolant hoses from addi‐ ra
c
tional heater. s
ce
e
nl
pt
du
Continuation for all vehicles
an
itte
y li
erm
ab
– Remove securing clamp -1- between particulate filter and tur‐
ility
ot p
bocharger.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew securing nuts above particulate filter bracket with
l purpos
ratchet ring spanner - T10384- .

– Unscrew securing nuts -arrows- of particulate filter bracket
nform
ercia
-A- on crankcase and remove bracket.

m
at
– Push particulate filter aside and secure on plenum chamber
om
ion
bulkhead by suitable means.
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
yi Co
op
Check that all hose and line connections between engine, gear‐ C py
t. rig
box and body have been detached.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Attach lifting tackle - 3033- as follows and take up weight of
»engine/gearbox assembly« in installation position using
workshop crane - VAS 6100- .
Vibration damper end:
• Position 2.
Flywheel end:
• Position 8.
– Remove securing bolts -arrows- of assembly mounting on en‐

gine.

– Remove securing bolts -arrows- of assembly mounting on the

gearbox.
Note
Carefully guide engine/gearbox assembly when removing to

avoid damaging the body.
– Lower engine/gearbox assembly slightly and remove for‐

AG. Volkswagen AG d
wards. lkswagen oes
n o ot g
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Secure engine to engine and gearbox support
ed
b
- VAS 6095- to ran
ris
carry out repairs ⇒ page 30 . ut
ho tee
or
a ac
ss
ce
e
1.1.2 Removing engine, CC

nl
pt
du
an
itte
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erm
ab
ility
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Note
wit
, is n
h re
♦ Read out radio anti-theft code as the battery earth strap has
hole
spec
to be disconnected during the next work steps.
es, in part or in w
t to the co
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties that are opened or cut through when the engine
rrectness of i
is removed must be renewed/replaced in the same position
when the engine is installed.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop AG. Volkswagen AG d

equipment required agen oes
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♦ Hose clamps up to 25 mm - rise
d
nte
3094- utho eo
ra
s a c
s
♦ Engine bracket - T10012-
ce
le
un
pt
an
♦ Torque wrench - V.A.G
d
itte
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1331-
rm
ab
pe
ility
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wit
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1332-
h re
hole
spec
♦ Engine and gearbox jack - es, in part or in w
V.A.G 1383 A-
t to the co
♦ Stepladder - VAS 5085-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hose clip pliers - VAS 6340-

♦ Drip tray for workshop hoist - VAS 6208-
Removing
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
– Disconnect electrical connector on air mass meter - G70- .
pipe ⇒ page 289 . lkswage es n
Vo ot gu
y
db ara
– Unscrew bolts -arrows- and remove air oduct
ris
e from lock carrier. nte
h eo
ut ra
– Remove battery ⇒ Electrical system;
ss Rep. gr. 27 ; Battery;
a c
ce
le
un
pt
an
d

itte
y li
erm
ab
Vehicles with air conditioning system:
ility
ot p
wit
is n
– Extract refrigerant from air conditioning system ⇒ Heating, air
h re
ole,
conditioning system; Rep. gr. 00 ; Repair instructions; Drain‐
spec
ing the refrigerant circuit .
Caution t to the co
rrectne
Danger of damage to air conditioner compressor, refrigerant

lines and hoses.
ss
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

o
cial p
f inform
mer
atio
m
– Unscrew refrigerant lines -arrows- from air conditioner com‐

o
n
c
i
or
pressor.
thi
te
sd
va
Continuation for all vehicles:

i
o
pr
cum
r
fo
en
– Remove engine control unit - J623- from its bracket

ng
t.
yi Co
⇒ page 297 . t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull engine wiring harness connector -arrow- off engine con‐

trol unit.
– Release feed-through for engine wiring harness -arrow- and

pull off upwards.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Unscrew bolts -arrows- and remove battery mounting bracket
, is n
h re
-1-.
hole
spec
– Separate connectors.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
♦ -1- Exhaust gas temperature sender 1 - G235-

te o
thi
s
iva
do

r
rp
cum
fo
en
g
♦ -3- Lambda probe - G39-

n
t.
yi Co
op py
♦ -4- Charge pressure control solenoid valve - N75-
. C rig
ht ht
rig by
opy Vo
– Unscrew the bolts -arrows- and place charge pressure control by c lksw
cted agen
solenoid valve - N75- with vacuum lines on the engine. Prote AG.
– Guide lines out of brackets on plenum chamber bulkhead and

on turbocharger.

– Disconnect quick-release couplings for heat exchanger

AG. Volkswagen AG d
-arrows- on plenum chamber bulkhead. ksw
agen oes
not
ol
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove coolant expansion tank -2- by undoing bolts -3-.
– Release and unplug connector from coolant expansion tank.
rrectness of i
– Place coolant expansion tank -2- on engine.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
– Unscrew bolt -arrow- (captivated nut), twist intake hose -A- Cop py
. rig
clockwise out of its bracket and remove.
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Pull off vacuum hoses -1- and -2- for charge air control.

– Slide the two clips in the direction of the -arrows- and remove
cover from E-box in engine compartment.
– Remove lines on the central electrical systemage-arrows-

n AG. Volksand
wagen AG
does
place on the engine. olksw not
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ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Open cable guide retainer -arrows-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect engine wiring harness connector -arrow- below left

headlight.

– Free connector -1- and disconnect.

– Open retainer -2- for wiring guide located below.
– Remove wiring harness for engine control unit from wiring duct
and place on engine.
– Pull vacuum hose -arrow- off brake booster.

Vehicles with dual clutch gearbox
34 ; Gear-change mechanism; Assembly overview - Gear- agen
AG. Volkswagen AG d
oes
change mechanism . Volksw not
gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– To release, turn catch of mechatronic connector -arrow- and
h re
ole,
pull connector off.
spec
t to the co
rrectne
change mechanism .
– Remove tube-hose line or plastic line from clutch slave cylin‐
ss
der ⇒ Rep. gr. 30 ; Clutch control mechanism; Removing and
o
cial p
f
installing lines for clutch control mechanism .
inform
mer
atio
om
– Disconnect all connectors between starter, gearbox and body.
n
c
i
or
n thi
te
sd
iva
WARNING
o
pr
cum
r
fo
en
ng
t.
yi
Danger of scalding from very hot fuel.
Co
Cop py
t. rig
gh
♦ In extreme cases, the temperature of the fuel and the fuel
ht
pyri by
lines can reach 100°C after the engine is switched off. Al‐
o Vo
by c lksw
cted agen
low the fuel to cool down before disconnecting the lines - Prote AG.
danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.

– Open quick-release fasteners -A- and -B- of fuel lines and pull
fuel lines off.
– Unclip bracket for coolant hose -1-.

– Remove fuel filter securing bolts and place fuel filter on engine.
– Unplug connector from pressure differential sender - G505-

-2-, unscrew securing bolts -1-. en AG. V
olkswagen AG
ag does
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Unclip lines for pressure differential sender - G505- out of up‐

orm
per toothed belt guard together with bracket -1-.

m
atio
om
n in
– Lay pressure differential sender - G505- on particulate filter

or c
together with bracket.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove securing clamp -1- between particulate filter and tur‐

bocharger.
– Remove bolt -1-.

– Removing radiator ⇒ page 222 .
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove lower right and left wheel housing liner parts.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Remove charge air line, loosen hose clips -1- and -2- for this.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Remove charge air line, loosen hose clips -1- and -2- for this.
inform
mer
– Seal open lines and unions with clean plugs from engine seal‐
atio
ing plug set - VAS 6122- .

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Disconnect connector -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unscrew bolts -1…3- and remove pendulum support.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Vehicles with auxiliary heater

o
n in
or c
thi
– Clamp off coolant hoses -1- and -2- with hose clips, up to
te
sd
iva
25 mm in diameter - 3094- and pull coolant hoses from addi‐
o
r
rp
cu
tional heater.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove nuts -1 and 2-.
– Tie up particulate filter to rear.
Caution
Avoid damage to the flexible joint.

♦ Do not bend flexible joint in front exhaust pipe more than
10°.

lkswage es n
o ot g
byV ua
CC 2012 ➤ , Golfir se Cabriolet 2012 ➤
d ran
tee
o
4-cylinder adiesel
uth engine (2.0 l engine, common rail, generation or
ac II) - Edition 09.2013
ss
ce
e
– Unscrew bolts -1- and remove heat shield for right drive shaft.
nl
pt
du
an
itte
y li
– Unbolt left and right drive shafts from flange shafts on gearbox.
erm
ab
ility
ot p
– Unscrew nuts (3 pc) of swivel joint on transverse link on right
wit
⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower trans‐
, is n
h re
verse link, swivel joint; Assembly overview – lower transverse
hole
spec
link, swivel joint .
es, in part or in w
t to the co
– Disconnect swivel joint from transverse link on right.
rrectness of i
l purpos
– Disconnect electrical connector -arrow- on oil level and oil
nform
ercia
temperature sender - G266- .

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen hose clip -2-.

– Remove bolts -arrows-.
– Disconnect electrical connection -1- on charge pressure send‐
er - G31- / intake air temperature sensor - G42- and remove
air pipe.
– Free coolant hose -3-.
– Unscrew securing bolt -arrow- for continued coolant circulation

pump.

– Remove front noise insulation -1- for sump, loosen securing

parts -arrows- for this.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Bolt engine bracketoris - T10012- with securing bolt -1- and nut
e nte
-2- to cylinderautblock
h (tightening torque: approx. 20 Nm). eo
ra
ss c
– Insert engine bracket - T10012- in engine and gearbox jack -
ce
e
nl
pt
V.A.G 1383 A- .
du
an
itte
y li
– Raise engine/gearbox assembly slightly.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
To reach bolts for assembly mounting use stepladder -

t.
yi Co
op
VAS 5085- .
C py
ht. rig
rig ht
py by
co Vo
by lksw
– Unscrew bolts -arrows- for engine mounting. Prote
cted AG.
agen

– Unscrew bolts -arrows- for gearbox mounting.
Caution
Danger of damage to hose and line connections as well as

engine compartment.
♦ Check that all hose and line connections between engine,
gearbox, subframe and body have been disconnected.
♦ When lowering, carefully guide engine/gearbox assembly
out of engine compartment.
♦ Ensure clearance to air conditioner compressor.
– First lower engine/gearbox assembly slightly.

– Then swing gearbox end of engine/gearbox assembly for‐
wards and only then lower further.
1.2 Separating engine and gearbox

⇒ “1.2.1 Separating engine and gearbox, manual gearbox”, page
26
⇒ “1.2.2 Separating engine and gearbox, dual-clutch gearbox”,
page 28
AG. Volkswagen AG d
agen oes
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1.2.1 Separating engine and gearbox, manual ol not
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♦ Hooks - 10 - 222 A /2-
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♦ Hook -2024 A /1- of lifting tackle - 2024 A-
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Unscrew bolts -arrows- and remove gearbox support.
– Unscrew bolts -1- and -2-, and remove starter from gearbox.
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– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and

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secure with pin -arrow-.

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spec
– Attach workshop hoist - VAS 6100- to lifting tackle with adapter

- 10 - 222 A /20- .
t to the co
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– Unscrew bolts -1, 2, 5, 6, 7, 8- from gearbox to engine con‐

nection.
– Pull gearbox off engine.
1.2.2 Separating engine and gearbox, dual-

clutch gearbox
♦ Adapter - 10 - 222 A /20-
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♦ Hook -2024 A /1- of lifting tackle - 2024 A-
ility
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Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Remove coolant hoses from gear oil cooler, loosen hose clips
-arrows- for this.
– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and

secure with pin -arrow-.
– Attach workshop hoist - VAS 6100- to lifting tackle with adapter
- 10 - 222 A /20- .
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– Free wiring harnesses -arrows- and electrical connector -1- at

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bracket.
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– Unscrew remaining bolts -1, 3, 5, 6, 7, 8, 9, 10- from gearbox

to engine connection.
Note
♦ Bolt -3- is only accessible after removing starter.

♦ Ignore -items 2, 4- and -A-.
– Pull gearbox off engine.
1.3 Securing engine on engine and gearbox

support
Before carrying out repair work, secure engine in engine and
gearbox support - VAS 6095/1- using universal mounting - VAS
6095- .
Special tools and workshop

equipment required
♦ Lifting tackle - 3033-
♦ Engine and gearbox jack -
V.A.G 1383 A-
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♦ Workshop hoist - VAS yV
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♦ Engine and gearbox sup‐ au ac
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4-cylinder diesel
s engine (2.0 l engine, common rail, generation II) c- Edition 09.2013
s
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an
Procedure
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– Separate engine from gearbox (vehicles with manual gearbox)
pe
ility
⇒ page 26 .
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– Separate engine from gearbox (vehicles with dual-clutch gear‐
hole
spec
box) ⇒ page 28 .
es, in part or in w
t to the co
– Attach lifting tackle - 3033- as follows and lift from engine and
gearbox jack - VAS 6100- using workshop crane - V.A.G 1383
A- .
rrectness of i
Flywheel end: position 4.
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Vibration damper end: position 8.

– Secure engine on engine and gearbox support - VAS 6095/1-
nform
ercia
using universal mounting - VAS 6095- .

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1.4.1 Notes on installing
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Install in reverse order. While doing so, note the following:

Repairing clutch ⇒ Rep. gr. 30 ; Clutch
– Check whether dowel sleeves for centring engine/gearbox
have been fitted in cylinder block, insert if necessary.
Fastening, manual gearbox to engine
Item Bolt Nm
1 1) M12x55 80
2 1) M12x165 80
3 M10x105 40
4 M10x50 40
5 2) M12x65 80
A Dowel sleeves for centralising
• 1) Bolt with M8 stud.
• 2) Bolted into gearbox from engine side.

Fastening, dual clutch gearbox to engine

Item Bolt Nm
1, 3, 10 M12x55 80
5 M12x65 80
6, 7, 8 M10x50 40
9 M12x70 80
2, 4 Securing starter ⇒ Electrical system; Rep.
gr. 27 ; Starter; Assembly overview -
Starter .
A Dowel sleeves for centralising
Note

– Install hydraulic line for the hydraulic clutch ⇒ Rep. gr. 30 ;
Clutch control mechanism; Removing and installing lines for
clutch control mechanism . wage
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– Install gearbox selector mechanism d b and adjust if necessary ⇒
y ara
Rep. gr. 34 ; Manual gearbox; r se
iRemoving and installing man‐ nte
ho eo
ual gearbox . s aut ra
c
s
– Bleed clutch control mechanism ⇒ Rep. gr. 30 ; Clutch control
ce
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un
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mechanism, Bleeding clutch control mechanism .
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– Install lay selector lever and adjust if necessary ⇒ Rep. gr.

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37 ; Manual gearbox; Removing and installing lay selector lev‐ h re

ole,
er .
spec
t to the co

– When installing engine and gearbox assembly, ensure there
is sufficient clearance to subframe and radiator.
rrectne
– Adjusting assembly mountings ⇒ page 39 .

ss o
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Note
form
mer
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♦ After working on particulate filter, ensure it is installed free of

o
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c
stress.
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♦ Renew self-locking nuts, seals, gaskets and securing clamps.

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Risk of damage to the flexible joint behind the particulate filter
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during removal and installation: Prote AG.
♦ Do not bend decoupling element more than 10°. Secure

with transportation lock - T10404- .
♦ Install decoupling element so that it is not under tension.
♦ Take care not to damage wire mesh on decoupling ele‐
ment.
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.

40 ; Drive shaft; Removing and installing drive shaft .

– Install the heat shield for the drive shaft on the right. Tighten
bolts -arrows- to do so.
– Install plenum chamber bulkhead ⇒ General body repairs,
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing and
installing plenum chamber cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier; Removing and installing lock carrier .
– Attach refrigerant lines ⇒ Heating, air conditioning system;
Rep. gr. 87 ; Air conditioner compressor; Installing and re‐
moving refrigerant lines on the air conditioner compressor .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .
– Install the battery and battery tray ⇒ Electrical system; Rep.
gr. 27 ; Battery; Removing and installing battery .
– Observe notes after connecting ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and reconnecting battery .
– Replenish coolant ⇒ page 189 . AG. Volkswagen AG d
agen oes
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– Filling fuel system ⇒ page 249 . d by V o gu
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– Read event memories of all control
ut
ho units. Erase fault memory eo
ra
entries which may have occurred
ss a during installation ⇒ Vehicle c
diagnostic tester “Vehicle self-diagnosis”.
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Specified torques y li
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Threaded connection Specified torque wit

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M5 4.5 Nm
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spec
Bolts, nuts M6 10 Nm
t to the co
M7 15 Nm
M8 20 Nm
rrectne
M10 40 Nm
M12 65 Nm1)
ss o
Manual gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox, Installing gearbox
cial p
f inform
Dual-clutch gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Specified torques for
mer
gearbox
atio
om
Air conditioner compressor ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compres‐
c
i
or
sor; Removing and installing air conditioning compressor from bracket

thi
te
sd
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Drive shaft ⇒ Running gear, axels, steering; Rep. gr. 40 ; Drive shaft; Assembly over‐
i
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view - Drive shaft

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Assembly mountings ⇒ “2.1 Assembly overview - assembly mountings ”, page 34
Co
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Particulate filter ⇒ “2.1.1 Assembly overview - front exhaust pipe with particulate filter”, page
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1) Specified torque for M12 collar bolts: 75 Nm

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings ”, page 34
⇒ “2.2 Supporting engine in installation position”, page 34
⇒ “2.3 Adjusting assembly mountings”, page 39
2.1 Assembly overview - assembly mount‐

ings
Engine assembly mountings
To remove and install, support the engine in mounting position
♦ A 1) = 40 Nm + 90° further
♦ B 1) = 60 Nm + 90° further
♦ C 1) = 20 Nm + 90° further
1) Renew.
Gearbox assembly mounting

♦ 1 1) = 40 Nm + 90° further
♦ 2 1) = 60 Nm + 90° further
1) Renew.
AG. Volkswagen AG d
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♦ A 1) = 50 Nm + 90° further
h re
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♦ B 1) = 50 Nm + 90° further spec

es, in part or in w
t to the co
♦ C 1) = 100 Nm + 90° further
1) Renew.
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2.2 Supporting engine in installation posi‐

ion
c
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ate
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⇒ “2.2.1 Supporting engine in installation position, Golf Cabrio ”,

um
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page 34
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2.2.1 Supporting engine in installation posi‐
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Prote AG.
tion, Golf Cabrio


♦ Support bracket - 10-222 A-
AG. Volkswagen AG d
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♦ Adapter - 10-222 A/3-ed b y V gu
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♦ Adapter - 10-222 A/18-
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♦ Adapter - 10-222 A/1-
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♦ Torque wrench - V.A.G 1331-

♦ Spring-type clip pliers - VAS 6362-
V277- and lay it to one side (fuel lines remain connected) ⇒
2. Assembly mountings 35
Fuel supply – diesel engines; Rep. gr. 20 ; Fuel pump; Re‐

moving and installing fuel pump .
– Fit support bracket - 10-222 A- with required adapters as
shown and take up weight of engine in installation position.
AG. Volkswagen AG d
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The securing bolts for the assembly mountings
ss a may only be re‐ c
moved if the engine is supported with the support bracket - 10-222
ce
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pt
A- ! du
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2.2.2 Supporting engine in installation posi‐
es, in part or in w
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♦ Adapter - 10 - 222 A /8-
nform
ercia
♦ Adapter - 10 - 222 A /18-

m
at
♦ Adapter - 10 - 222 A /3-
om
ion
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♦ Hook - 10 - 222 A /10-

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Procedure
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route lines of any kind so that the original routing can be
restored.
hot components.

– Remove air filter housing ⇒ page 289 .

– Remove intake hose between air masswameter
gen AG- G70- and
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To prevent damage to the electronic components when dis‐
pt
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connecting the battery :
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♦ Observe notes on procedure for disconnecting the bat‐
ility
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– Disconnect earth wire -arrow- from battery with ignition switch‐
t to the co
ed off ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnect‐
ing and reconnecting battery .
rrectness o
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mer
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– Remove battery and battery tray -arrows-.
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-2-, unscrew securing bolts -1-.

together with bracket. en AG. V
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– Fit support bracket - 10-222 A- with required adapters
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shown and take up weight of engine in installation
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Caution
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Ensure that the adapters are not on the bolted connections
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-arrows- of the front end. It could otherwise cause deforma‐
pe
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tions.
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Note
rrectness of i
The securing bolts for the assembly mountings may only be re‐
l purpos
moved if the engine is supported with support bracket - 10-222

A- !
nform
mercia
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2.3 Adjusting assembly mountings
WARNING

AG. Volkswagen AG d
tions: olkswagen oes
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♦ Route lines of any kind so that the original
ris
ed routing can be ara
nte
restored. utho eo
ra
sa c
♦ Ensure that there is sufficient sclearance to all moving or
ce
hot components. le
un
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– Supporting the engine in its installation position ⇒ page 34 .
wit
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spec
Note
t to the co
The securing bolts for the assembly mountings may only be re‐
moved if the engine is supported with the support bracket - 10-222
A- !
rrectne
– Renew engine mounting bolts -arrows- one after the other (if
ss o
not already carried out) and screw in hand-tight.
cial p
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mer
atio
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– Renew gearbox mounting bolts -arrows- one after the other (if
not already carried out) and screw in hand-tight.
– Loosen bolts for support arms on engine side and on gearbox
side by approx. two turns each.
Engine mounting
• There must be a distance -a- of at least 10 mm between engine
bracket and longitudinal member (right side).
• The side surface of the engine bracket -2- should be located
parallel to the support arm -1-.
Gearbox mounting wage

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Vo
– Ensure that edges of support armed(on gearbox side) -1- and
by ua
ran
gearbox mounting -2- are parallel.
horis tee
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a ac
• Dimension -x- must be identical
ss on both sides of mounting.
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– Tighten bolts for assembly mountings:
du
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• Specified torques ⇒ page 34 .
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• Ensure that fuel lines are tight.
hole
spec
es, in part or in w
• Do not interchange supply line and return line (return line blue
t to the co
or with blue marking, supply line black).
– Observe notes after connecting battery ⇒ Electrical system;
rrectness of i
Rep. gr. 27 ; Battery; Disconnecting and reconnecting battery .
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
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t.
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AG. Volkswagen AG d
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not CC 2012 ➤ , Golf Cabriolet 2012 ➤
yV gu
e4-cylinder
d b diesel engine (2.0 l engine, arcommon
ante rail, generation II) - Edition 09.2013
ris
tho eo
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ss
3 engine cover panel
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nl
pt
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itte
⇒ “3.1 Removing and installing engine cover panel”, page 41
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3.1 Removing and installing engine cover
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panel
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Removing
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Caution
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Bracket for engine cover panel on cylinder head cover may
l purpos
break off if removed improperly. Always remove engine cover

panel according to following instructions.
nform
mercia
– Pull engine cover panel upwards out of fastening elements in
at
om
io
areas of -arrows- and in sequence shown. To do this, grip as
n
c
in t
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far as possible beneath engine cover panel.

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Installing
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Caution t. Cop py
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Ensure that the 4 fasteners (ball sockets) are correctly posi‐
op Vo
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tioned before installing the engine cover panel; if necessary,
agen
Prote AG.
move them into the correct position. Otherwise the engine cov‐
er panel may be damaged.
– Press engine cover panel ball sockets into correct position.

– Position engine cover panel on securing points and press cor‐
ners into fasteners.
3. engine cover panel 41

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 42
⇒ “1.2 Removing and installing poly V-belt”, page 46
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 49
⇒ “1.4 Removing and installing ancillary bracket”, page 50
⇒ “1.5 Removing and installing engine bracket”, page 52
⇒ “1.6 Assembly overview - cylinder block (pulley end)”,
page 59
⇒ “1.7 Removing and installing sealing flange on pulley end”, agen
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page 61 olksw not
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⇒ “1.8 Renewing crankshaft oil seal - belt pulley end”, horis tee
page 63 au
t or
ac
ss
1.1 Assembly overview - poly V-belt drive
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⇒ “1.1.1 Assembly overview - poly V-belt drive with tensioning
erm
ab
element and air conditioner compressor”, page 42
ility
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⇒ “1.1.2 Assembly overview - poly V-belt drive with tensioning
h re
ole,
roller and air conditioner compressor”, page 44
spec
⇒ “1.1.3 Assembly overview - poly V-belt drive without air condi‐
t to the co
tioning compressor ”, page 46
1.1.1 Assembly overview - poly V-belt drive with tensioning element and air con‐
rrectne
ditioner compressor
ss o
cial p
f inform
mer
atio
om
n
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or
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Prote AG.
42 Rep. gr.13 - Crankshaft group

1 - Belt pulley and vibration

damper
❑ Assembly through offset
holes only possible in
one position.
2 - 25 Nm
3 - Alternator
4 - Bracket
❑ For ancillaries
❑ Removing and installing
⇒ page 50
5 - 20 Nm + turn 180° further
❑ Renew.
6 - Poly V-belt tensioning ele‐
ment
⇒ page 49
7 - Air conditioner compressor
8 - 45 Nm
9 - Dowel sleeves
10 - Poly V-belt
❑ mark direction of rota‐
tion before removing
❑ check for wear
❑ do not kink
⇒ page 46
AG. Volkswagen AG d
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43
cop Vo
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Prote
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agen 1. Cylinder block (pulley end)
1.1.2 Assembly overview - poly V-belt drive with tensioning roller and air condi‐
tioner compressor
1 - Poly V-belt
❑ check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped
marker pen.
⇒ page 48
❑ do not kink
❑ When installing, make
sure it is properly seated
on poly V-belt pulleys.
2 - Tensioning roller for poly V-
belt
⇒ page 48
❑ Coat guide surfaces
with lubricating paste;
lubricating paste ⇒
Electronic Parts Cata‐
logue (ETKA) .
3 - Vibration damper
❑ with poly V-belt pulley n AG. Volkswagen AG do
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❑ Assembly through offset yV
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❑ Installation position: ss
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must align over protru‐

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itte
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sion on crankshaft pul‐

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ab
ley.
ility
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4 - 10 Nm + 90°
h re
hole
❑ Renew.
spec
es, in part or in w
❑ only use genuine bolts

t to the co
⇒ Electronic Parts Catalogue (ETKA) .

5 - Dowel sleeve
rrectness of i
❑ Check for correct seating in ancillary bracket.

l purpos
6 - 20 Nm + 90°
7 - 50 Nm + 90°
nf
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8 - Guide roller
m
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❑ For toothed belt

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9 - 15 Nm
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10 - Guide roller
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❑ For toothed belt

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11 - Bracket for ancillaries ht. rig
rig ht
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❑ Removing and installing ⇒ page 50 co Vo
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Prote AG.
12 - High-pressure pump
❑ Removing and installing ⇒ page 268

13 - Bolt
❑ Specified torque and tightening sequence ⇒ page 52 .
14 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
15 - 20 Nm
16 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compressor;
Removing and installing air conditioning compressor from bracket
17 - 45 Nm
18 - Dowel sleeve
❑ Check for correct seating in ancillary bracket.
19 - Bolt
Tensioning roller for poly V-belt - specified torque and tightening

sequence
Note
lkswage es n
♦ Replace bolt for tensioning roller. d byV
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ua
ran
ir se tee
♦ Use a brush to coat guide surfaces of tensioning
utho roller with or
solid lubricating paste; Solid lubricating
ss paste ⇒ Electronic
a ac
Parts Catalogue (ETKA) .
ce
le
un
pt
an
d
itte
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– Tighten bolt in 5 stages.
rm
ab
pe
ility
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Specified torques
h re
hole
spec
Stage Bolt Specified torque/turning further angle
es, in part or in w
t to the co
1 -Arrow- Screw in to contact by hand.
• The poly V-belt is tensioned
2 -Arrow- Turn until tensioning roller bolt reaches stop rrectness of i

• The poly V-belt is tensioned further
l purpos
3 -Arrow- Turn back 90°

nform
ercia
4 -Arrow- 30 Nm
m
5 -Arrow- Turn 90° further

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tion in
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Prote AG.
1. Cylinder block (pulley end) 45

CC 2012 ➤ , Golf Cabriolet 2012 ➤ n AG. Volkswagen AG do
wage e
4-cylinder diesel engine (2.0 l engine,y Vcommon
olks rail, generation II) -s nEdition
ot g 09.2013
b ua
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1.1.3 Assembly overview - poly V-belt drive without air conditioning compressor tho
or
ac au
ss
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nl
pt
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an
1 - Vibration damper
itte
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erm
ab
❑ Installation position:
ility
ot p
hole in vibration damper
wit
must align over protru‐
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h re
sion on crankshaft pul‐
hole
spec
ley.
es, in part or in w
t to the co
2 - 25 Nm
3 - Alternator
rrectness of i
4 - Bracket for ancillaries
l purpos
5 - Poly V-belt
❑ Renew.
nf
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⇒ page 49
atio
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Prote AG.
1.2 Removing and installing poly V-belt

⇒ “1.2.1 Removing and installing poly V-belt (poly V-belt drive with
tensioning element and air-conditioning compressor)”,
page 46
⇒ “1.2.2 Removing and installing poly V-belt (poly V-belt drive with
tensioning roller and air-conditioning compressor)”, page 48
⇒ “1.2.3 Removing and installing poly V-belt (poly V-belt drive
without air conditioner compressor)”, page 49
1.2.1 Removing and installing poly V-belt

(poly V-belt drive with tensioning ele‐
ment and air-conditioning compressor)

♦ Locking pin - T10060 A-
AG. Volkswagen AG d
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Removing
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erm
ab
ility
ot p
wit
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sulation .
ole,
spec
– Mark direction of rotation of poly V-belt.
t to the co
– Swing tensioning device in direction of arrow to relieve tension
on poly V-belt.
rrectness o
cial p
f inform
mer
atio
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c
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– Align holes -arrows- and lock tensioning element in position Cop py
t. rig
with locking pin - T10060 A- . opyri
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– Remove poly V-belt. Prote
cted AG.
agen
Installing
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are installed.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.

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gen AG does
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CC 2012 ➤ , Golf Cabriolet 2012y➤ Volk not
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b ara
4-cylinder diesel engine (2.0 rils engine, common rail, generation II) - Edition
e d
nte 09.2013
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– Fit poly V-belt on poly V-belt pulley.
ss c
ce
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un
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1- Crankshaft
an
d
itte
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erm
2- Tensioning element
ab
ility
ot p
3- Alternator
wit
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4- Air conditioner compressor
spec
– Start engine and check that belt runs properly.
t to the co
rrectness
o
cial p
f in
(poly V-belt drive with tensioning roller
form
mer
and air-conditioning compressor)
atio
om
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Removing
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sulation .
t.
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Cop py
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Caution copy Vo
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Prote AG.
If a used belt runs in the opposite direction when it is refitted,
this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tipped pen for re-installation.
– To slacken poly V-belt, unscrew tensioning screw -arrow-, re‐

move tensioning roller.
– Remove poly V-belt.
Installing
Note
♦ Replace bolt for tensioning roller.

♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
nator and air conditioner compressor) are installed.
– Fit poly V-belt on poly V-belt pulley:

1- Vibration damper
2- Tensioning roller
3- Alternator
4- Air conditioner compressor
– Use a brush to coat guide surfaces of tensioning roller with
solid lubricating paste; Solid lubricating paste ⇒ Electronic
– Insert tensioning roller with its pin into guide on bracket for
ancillaries.

– Tighten bolt for tensioning roller ⇒ page 45 .
– Check whether end of bolt for tension roller projects over ten‐
sioning roller running surface by dimension -a-.
• Dimension -a- = about 2.5 mm.
• This ensures that the bolt has been tightened to its end stop.
– Start engine and check that poly V-belt
olks runs properly.
wage es n
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V
by ua
– Install noise insulation ⇒ Generalris
ed
body repairs, exterior; Rep. ran
tee
gr. 66 ; Noise insulation; Assembly
autho
overview - noise insula‐ or
ac
tion . ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
(poly V-belt drive without air conditioner
ole,
spec
compressor)
t to the co
♦ Poly V-belt repair kit with assembly tools ⇒ Electronic Parts
Catalogue (ETKA) rrectness o
cial p
Note
inform
mer
The poly V-belt repair kit with tools contains tool -T10367- and
atio
m
illustrated instructions.
o
n
c
i
or
n thi
te
sd
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– Remove noise insulation or skid plate ⇒ General body repairs,

iv
o
pr
exterior; Rep. gr. 66 ; Noise insulation; Assembly overview -

um
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fo
en
noise insulation .
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t.
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– Loosen right wheel housing liner in front area. t. C rig
gh ht
pyri by
– Cut through poly V-belt.
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by c lksw
cted agen
Prote AG.
– Proceed as described in illustrated instructions.
– Secure front part of right wheel housing liner again.
– Install noise insulation or skid plate ⇒ General body repairs,
noise insulation .
1.3 Removing and installing tensioner for

poly V-belt
Removing


sulation .
– Remove poly V-belt ⇒ page 46 .
– Remove charge air cooler ⇒ page 240 .
– Unscrew securing bolt -2- and remove tensioning element for
poly-V belt -1-.
Installing
– Renew bolt for tensioning element. gen AG. Volkswagen AG d
wa oes
olks not
– Install poly V-belt ⇒ page 46
db .
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– Replenish coolant ⇒ upage
tho 189 . eo
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ss
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nl
pt
du
an
itte
y li
erm
ab
ility
Specified torques
ot p
wit
, is n
h re
Component Specified torque
hole
spec
Tensioning element ⇒ “1.1.1 Assembly overview - poly V-belt drive with tensioning element and air con‐
es, in part or in w
ditioner compressor”, page 42
t to the co
Charge air cooler ⇒ “2.2 Removing and installing charge air cooler”, page 240
rrectness of i
l purpos
1.4 Removing and installing ancillary brack‐

et
nf
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orm
Removing
m
atio
om
n in

or c
thi
te
– Remove high-pressure pump ⇒ page 268 .

sd
iva
o
r
rp
cu
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐

o
m
f
en
ng
nator; Removing and installing alternator .

t.
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Cop py
ht. rig
rig ht
by
WARNING copy Vo
by lksw
cted agen
Prote AG.
The air conditioner refrigerant circuit must not be opened.
– Unscrew air compressor from the bracket for auxiliary equip‐

ment and mount on the lock carrier ⇒ Heating, air conditioning
system; Rep. gr. 87 ; Air compressor; Installing and removing
air compressor from the bracket .

AG. Volkswagen AG d
agen oes
olksw not
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thor CC e 2012
or ➤ , Golf Cabriolet 2012 ➤
u
4-cylinder
ss a diesel engine (2.0 l engine, common rail, generation
ac II) - Edition 09.2013
ce
e
nl
pt
du
– Unscrew securing bolt for engine bracket -1-.
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Unscrew idler pulleys -1- and -2-, and unscrew toothed belt
orm
guard bolt -arrow-.
m
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Cop py
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Prote AG.
– Unscrew bolts -1- to -6- and remove bracket for auxiliary

equipment.
Installing
♦ Note any fitted sleeves in ancillary bracket and renew missing
ones if necessary.
♦ Renew all bolts to be tightened with further turning angle.

4-cylinder diesel engine (2.0 l engine, common rail,. Vgeneration
gen AG
olkswagen AGII) - Edition 09.2013
d wa oes
olks not
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Ancillary bracket - specified torques and tightening
ed
b sequence ara
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– Insert securing bolts for ancillary bracket
au
t
as follows: ra
c
ss
♦ Bolts -1- and -2- M10 x 52.
ce
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nl
pt
du
an
itte
♦ Bolts -5- and -6- M10 x 60.
y li
erm
ab
ility
♦ Bolts -3- and -4- M10 x 30.
ot p
wit
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– Tighten securing bolts for ancillary bracket in sequence
h re
hole
-1 … 6- in 2 stages as follows:
spec
es, in part or in w
1. Screw all bolts in to stop by hand.
t to the co
2. Tighten all bolts to 40 Nm.
rrectness of i
3. Turn bolts -3- and -4- 45° further.
l purpos
4. Turn bolts -1, 2, 5 and 6- 90° further.

– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
nf
ercia
Removing and installing alternator .
orm
m
– Installing high-pressure pump ⇒ page 268 .
atio
om
n in
c
– Replace the front bolt of the motor mounting and tighten it

or
thi
e
⇒ Item 32 (page 109) (32).

t
sd
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1.5 Removing and installing engine bracket
f
en
ng
t.
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Cop py
⇒ “1.5.1 Removing and installing engine bracket, Golf Cabrio”,
t. rig
gh ht
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page 52 p by
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⇒ “1.5.2 Removing and installing engine bracket, CC”, Prote AG.
page 55
1.5.1 Removing and installing engine bracket,

Golf Cabrio
♦ Support bracket - 10 - 222 A-
♦ Adapter - 10 - 222 A /3-

♦ Adapter - 10 - 222 A /1-
AG. Volkswagen AG d
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Removing
itte
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ility
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Note
spec
es, in part or in w
t to the co
♦ The assembly mounting may only be removed if the engine is
supported in the installed position ⇒ page 34 !
rrectness of i
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
l purpos

nf
ercia
V277- , and lay it to one side (fuel lines remain connected) ⇒

or

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– Supporting the engine in its installation position ⇒ page 34 .

thi
te
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.

– Unscrew bolts -B- and -C-.

– Unscrew bolts -A- and remove the engine mounting.
– Remove front right wheel housing liner: ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing
and installing wheel housing liner .
WARNING
When raising and lowering engine using support bracket -

10-222A- , ensure that no components/hoses are damaged,
overstretched or torn off.
Note
The securing bolt -1- is accessible through an aperture in the

wheel housing. Raise and lower the engine via the spindle of the
support bracket - 10 - 222 A- , if necessary, to remove or fit bolts
-2- and -3-.
– Unscrew securing bolts of engine bracket in the sequence

-3 -, -2 - and -1-.
– Remove engine bracket upwards.
Installing
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the n AG. Volkswagen AG do
engine bracket may be stressed, causing it to break. lkswage es n
Vo ot g
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– Install engine bracket from above. au ac
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Note
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ab
pe
ility

ot
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wheel housing. Raise and lower the engine via the spindle of the
h re
hole
support bracket - 10 - 222 A- , if necessary, to remove or fit bolts

spec
-2- and -3-.

es, in part or in w
t to the co
– First tighten the mounting bolts in the sequence -1-, -2- and
-3- hand tight.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
orise CC 2012 nte➤ , Golf Cabriolet 2012 ➤
h eo
4-cylinder adiesel
ut engine (2.0 l engine, common rail, generation r a II) - Edition 09.2013
c
ss
ce
e
nl
Tightening sequence for engine bracket
pt
du
an
itte
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Tighten the mounting bolts in the sequence -1-, -2- and -3-.
erm
ab
ility
ot p
1- Pre-tighten with torque wrench:
wit
, is n
h re
Stage I = 8 Nm hole
spec
Stage II = 40 Nm
es, in part or in w
t to the co
2- Turn further with rigid spanner:
Stage III = 90°
rrectness of i
Stage IV = 90°
l purpos
– Tighten mounting bolts to the prescribed torque in the speci‐

fied sequence ⇒ Item 32 (page 109) .
nf
ercia
orm
m
– Fit engine mounting, tighten bolts -A- first and then -C-
atio
m
⇒ page 34 .
o
n in
or c
thi
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– Use the spindle to bring the engine bracket to rest on the as‐
t
sd
iva
sembly mounting.
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f
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ng
– Place bolts -B- in position and tighten them ⇒ page 34 . yi

t.
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♦ Ensure that fuel hose connections are tight.
t. C rig
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♦ Do not interchange supply line and return line (return line blue
o
by c lksw
cted agen
or with blue marking, supply line black). Prote AG.
Specified torques
Assembly mountings ⇒ “2 Assembly mountings”, page 34
1.5.2 Removing and installing engine bracket, CC


equipment required
♦ Adapter - 10 - 222 A /8-
♦ Adapter - 10 - 222 A /18-
♦ Adapter - 10 - 222 A /3-
♦ Hook - 10 - 222 A /10-
AG. Volkswagen AG d
agen oes
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nl
pt
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ab
ility
ot p
Removing
wit
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hole
spec
– Remove intake line between air mass meter - G70- and tur‐
es, in part or in w
t to the co
bocharger.
rrectness of i
l purpos
nf
ercia
orm
m
atio
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t.
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Prote AG.

– Unplug connector from pressure differential sender
olks
w- aG505-
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-2-, unscrew securing bolts -1-. db
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wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
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en
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– Bracing the engine in its installation position ⇒ page 36 .

t.
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Cop py
ht. rig
rig ht
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Note by c lksw
cted agen
Prote AG.
♦ The assembly mounting may only be removed if the engine is

supported with support bracket 10-222A!
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
– Unscrew bolts -B- and -C-.
– Unscrew bolts -A- and remove engine mounting.

– Unscrew coolant line securing bolt -arrow-.

– Remove front right wheel housing liner: ⇒ Generalwbody gen Are‐
G. Volkswagen AG d
pairs, exterior; Rep. gr. 66 ; Wheel housing liner;ol s a
kRemoving
oes
not
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and installing wheel housing liner . ise
d b ara
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ho
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ac
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Unscrew bottom coolant line securing bolt -arrow-.
t to the co
WARNING
rrectness of i
When raising and lowering engine using support bracket -
l purpos
10-222A- , ensure that no components or hoses are damaged,

overstretched or torn off.
nform
mercia
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
c
um
for
wheel housing. If necessary, raise and lower engine using spindle
en
ng
t.
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of support bracket - 10 - 222 A- to remove or start bolts -2- and Cop py
-3-.
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew securing bolts of engine bracket in sequence
-3…1-.
– Remove engine bracket upwards.
Installing
Install in reverse order. In the process, note the following:
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the
engine bracket can be stressed, causing it to break.
– Install engine bracket from above.
Note

wheel housing. If necessary, raise and lower engine using spindle
of support bracket - 10 - 222 A- to remove or start bolts -2- and
-3-.
– Screw in new bolts in sequence -1 ... 3- until finger-tight ini‐

tially.

Tightening sequence for engine bracket

– Tighten securing bolts to prescribed torque in specified se‐
quence ⇒ Item 32 (page 109) .
– Fit engine assembly mounting in position. First tighten bolts

-A- and then -C-. Specified torque ⇒ page 34 .
– Use the spindle to bring the engine bracket to rest on the as‐
sembly mounting.
– Locate bolts -B- and tighten them. Specified torque
⇒ page 34 .
Further assembly is basically the reverse of the dismantling se‐
quence. In the process, note the following:
gen A n AG d G. Volkswage
♦ Ensure that fuel hose
Volkconnections
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db ar
♦ Do not interchange
ris
e supply and return lines (return line blue
an
tee or
tho
with blue markings, supply line black). or
au a c
ss
Specified torques
ce
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nl
pt
du
an
itte

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erm
ab
ility
Assembly mountings ⇒ “2 Assembly mountings”,

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page 34
wit
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hole
spec
1.6 Assembly overview - cylinder block (pulley end)

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
en
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 - Bolt
❑ Renew after removing
❑ Loosen and tighten with
counterhold - 3415-
❑ Do not additionally oil
the thread and shoulder.
❑ 180 Nm +135° (turning
further to torque angle
can be performed in
stages, e.g. 90° + 45°)
2 - Crankshaft toothed belt pul‐
ley
❑ Contact surface be‐ AG. Volkswagen AG d
agen
tween toothed-belt pul‐ Volksw
oes
not
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ley and crankshaft must d by ara
have no oil on it. rise nte
tho eo
u ra
❑ Fitting possible in one ss a c
position only.
ce
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nl
pt
du
an
3 - Seal
itte
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erm
ab
❑ Do not additionally oil or
ility
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grease the oil seal seal‐
wit
, is n
ing lip.
h re
hole
❑ Before installing, re‐
spec
move oil residue from
es, in part or in w
t to the co
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
rrectness of i
seal on belt pulley end
⇒ page 63 .
l purpos
4 - Sealing flange
nform
ercia
❑ Must seat on dowel

pins.
m
at
om
i
on
c
⇒ page 61 in t
or
his
ate
❑ Install with silicone sealant - D 176 404 A2- ⇒ page 61 .

do
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or
5 - Cylinder block
f
en
ng
t.
yi Co
❑ Removing and installing crankshaft ⇒ page 79 . t. Cop py
rig
❑ Dismantling and assembling pistons and conrods ⇒ page 82
gh ht
pyri by
Vo
co lksw
by
6 - Dowel pin cted agen
Prote AG.
❑ Qty. 2
7 - Bolt
Sealing flange at belt pulley end - Prescribed torque and tighten‐

ing sequence
– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts Specified torque
1 -1 … 10- Screw in to contact by hand.
2 -1 … 6- In diagonal sequence and in stages;
final torque 15 Nm
3 -7 … 10- 15 Nm

1.7 Removing and installing sealing flange on pulley end

equipment required
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
♦ Torque wrench (5 - 50 Nm)
- V.A.G 1331-
♦ Torque wrench (40 - 200
Nm) - V.A.G 1332-
♦ Hand drill with plastic brush
♦ Silicone sealant - D 176
404 A-
♦ Flat scraper
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Removing
s
– Remove toothed belt ⇒ page 110 .

s o
cial p
– Remove crankshaft toothed-belt pulley. To do this, lock tooth‐

inform
ed belt pulley using counterhold - 3415- .

mer
atio
m
– Drain off engine oil.

o
n
c
i
or
– Remove sump ⇒ page 156 .

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew the front sealing flange by unscrewing bolts -1- to

-10-.
– Remove sealing flange; if necessary, loosen with light blows
using a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Remove residual sealant on sealing flange using a rotating
ce
e
nl
pt
du
plastic brush (wear protective goggles).
an
itte
y li
erm
ab
– Clean sealing surfaces.
ility
ot p
• Sealing surfaces must be free of oil and grease.
wit
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
♦ Observe use-by-date of sealant.

♦ The sealing flange must be installed within 5 minutes of ap‐
nform
ercia
plying the silicone sealant.

m
at
om
ion
c
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
in t
or
his
e
3 mm).
at
do
priv
cum
for
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
♦ The sealant bead must be no thicker than 2 - 3 mm. Excess yri
p by
o Vo
sealant can find its way into the sump and block the strainer
c by lksw
cted agen
in the suction line or drip on the sealing surface of the crank‐
Prote AG.
shaft seal.
♦ Before applying sealant bead, cover the sealing surface of the
sealing ring with a clean cloth.

– Apply silicone sealant bead as shown to clean sealing surface

of sealing flange.
– Fit the sealing flange immediately and lightly tighten all bolts.
Note
When fitting sealing flange with oil seal installed, use guide sleeve
- T10053/1- .
– Tighten sealing flange securing bolts diagonally

agen to 15 Nm. AG do
AG. Volkswagen
w es n
olks ot g
– Install crankshaft pulley ⇒ Item 2 (page
ed
by 60) .
V ua
ran
ris tee
– Install sump ⇒ page 156 . utho or
a ac
ss
– Install toothed belt ⇒ page 110 .
ce
le
un
pt
an
d
itte
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erm
ab
Note
ility
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wit
is n
Sealing compound must dry for approx. 30 minutes after instal‐
h re
ole,
lation. Only then fill with engine oil.
spec
t to the co
Specified torques
rrectne
Bolts for the sealing flange 15 Nm
s
♦ Tighten in diagonal sequence
s o
cial p
f in
Central bolt for crankshaft timing-belt 120 Nm + 90°
form
mer
pulley
atio
m
♦ Renew.
o
n
c
i
or
n thi
e
Toothed belt ⇒ “2.2 Removing and installing toothed belt”, page 110
t
sd
iva
o
r
Oil sump ⇒ “1.2 Removing and installing oil sump”, page 156
p
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
1.8 Renewing crankshaft oil seal - belt pulley end
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
♦ Oil seal extractor - 3203-
♦ Torque wrench (5 - 50 Nm)
- V.A.G 1331-
♦ Torque wrench (40 - 200
Nm) - V.A.G 1332-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Removing utho eo
ra
s a c
– Remove toothed belt ⇒ page 110 . s
ce
le
un
pt
– Remove crankshaft pulley. To do this, lock toothed belt pulley

an
d
itte
y li
using counterhold - 3415- .

rm
ab
pe
ility
– To guide seal extractor - 3203- , screw the centre bolt into

ot
wit
, is n
crankshaft by hand to stop.

h re
hole
spec
– Unscrew the inner part of oil seal extractor 2 turns (approx. 3

es, in part or in w
mm) from the outer part and lock in position with the knurled
t to the co
screw.
– Lubricate threaded head of oil seal extractor.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
64
cop Vo
by lksw
Rep. gr.13 - Crankshaft group Prote
cted AG.
agen
– Screw oil seal extractor forcibly as far as possible into oil seal.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
– Fit guide sleeve - T10053/1- onto crankshaft journal.

– Slide seal over guide sleeve onto crankshaft journal.
– Press oil seal in as far as stop with press sleeve - T10053- and
central bolt. G. Volkswagen nA AG do
wage e
– Install crankshafty Vtoothed-belt
olks pulley ⇒ Item 2s(page
not
gu 60) . b ara
ed
– Install andthotension
ris toothed belt ⇒ page 110 . nte
e or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
Specified torques
t to the co

rrectness of i
Central bolt for crankshaft timing belt pulley 120 Nm + 90°

♦ Renew.
l purpos
Toothed belt ⇒ “2.2 Removing and installing toothed belt”, page 110
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 66
⇒ “2.2 Removing and installing flywheel”, page 67
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 69
2.1 Assembly overview - cylinder block,

gearbox end
Repairing the clutch:
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox;
Rep. gr. 30 ; clutch .
♦ Vehicles with dual-clutch gearbox ⇒ 6-speed dual-clutch gear‐
box; Rep. gr. 30 ; clutch .
1 - Bolt
❑ Renew.
❑ 60 Nm + 90°
2 - Dual-mass flywheel
⇒ page 67 AG. Volkswagen AG d
agen oes
❑ Assembly through offset olksw not
yV gu
holes only possible in ed b ara
nte
is
one position. thor eo
au ra
c
3 - Sender wheel ss
ce
le
un
❑ For engine speed send‐

pt
an
d
itte
er - G28- .
y li
erm
ab
4 - Engine speed sender -

ility
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G28-
wit
is n
h re

ole,
spec
⇒ page 358
t to the co
5 - 5 Nm
6 - Dowel pin
rrectne
❑ Qty. 2
7 - Intermediate plate
ss o
❑ Do not damage or bend

cial p
f in
when assembling
form
mer
⇒ page 67 .
atio
m
8 - Sealing flange on flywheel

o
n
c
i
or
end
thi
te
sd
a
❑ With shaft seal

iv
o
pr
cum
r
❑ Renew. ⇒ page 69 .
fo
en
ng
t.
yi Co
9 - Bolt ht. Cop py
rig
❑ Specified torque and rig ht
py by
Vo
tightening sequence
co lksw
by
cted agen
⇒ page 67 . Prote AG.

Install intermediate plate

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel sleeves -arrows at bottom-.
Sealing flange on flywheel pulley end - specified torque and tight‐

ening sequence
– Tighten bolts in 2 stages in the sequence shown:
Stag Bolts Specified torque AG. Volkswagen AG d
e lksw
agen oes
not
V o gu
y
1 -1- to -6- Screw in to contact by isehand.
d b ara
nte
or eo
2 -1- to -6- In diagonal sequence
auth
and in stages; ra
final torque 15 Nm
ss c
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le
un
pt
an
d
itte
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ab
pe
ility
ot
2.2 Removing and installing flywheel
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Cylinder block, gearbox end 67

Removing
• Gearbox removed:
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox;
Rep. gr. 34 ; Removing and installing gearbox; Remove gear‐
box .
♦ Vehicles with dual-clutch gearbox ⇒ 6-speed dual-clutch gear‐
box; Rep. gr. 34 ; Removing and installing gearbox; Remove
gearbox .
Caution
Risk of damage to dual-mass flywheel.

AG. Volkswagen AG d
agen
♦ Screw out bolts -B- not with an
Voair
lkswwrench or power impact
es n o
ot g
wrench but by hand. sed by ua
ran
i tee
or
♦ When unscrewing the au bolts, make sure that the bolt heads
th or
ac
do not touch the dual-mass
ss
flywheel.
ce
le
un
pt
♦ Rotate dual-mass flywheel -A- so that bolts -B- align cen‐
an
d
itte
trally with the holes -arrows-.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Insert counterhold tool - 3067- in the hole in cylinder block
spec
-item B- and loosen bolts for dual-mass flywheel.
t to the co
– Unscrew bolts and remove dual-mass flywheel.
Installing
rrectne
ss o
cial p
Note
inform
mer
Renew dual-mass flywheel bolts.

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olkswCC 2012 ➤ , Golf Cabriolet not 2012 ➤
byV gu
ara
4-cylinder diesel engine (2.0 l engine,riscommon rail, generation II) - Edition 09.2013
ed
nte
ho eo
aut ra
– Insert counterhold tool - 3067- in hole in cylinder
s block
s c
ce
le
-item A-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
Specified torques
um
r
fo
en
ng
t.
yi Co
Component Specified torque . Cop py
rig
ht
Bolts for dual-mass flywheel ⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
rig ht
py by
o Vo
page 66 by c lksw
cted agen
Prote AG.
2.3 Removing and installing sealing flange

on gearbox side
⇒ “2.3.1 Pressing out sealing flange with sender wheel”,
page 70
⇒ “2.3.2 Pressing in sealing flange with sender wheel”,
page 72


equipment required
♦ Torque wrench -
V.A.G 1331-
♦ 24AF insert tool - V.A.G
1332/11-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Vernier gauge
rrectness of i
♦ 3 hexagon bolts M6 x 35 mm
l purpos
♦ 2 hexagon bolts M7 x 35 mm
nform
ercia
2.3.1 Pressing out sealing flange with sender

m
wheel
at
om
ion
c
in t
r
– Remove gearbox.
o
his
ate
do
riv
♦ Vehicles with manual gearbox ⇒ 6-speed manual gearbox

p
cum
or
02Q; Rep. gr. 34 ; Removing and installing gearbox; Remove

f
en
g
gearbox .
n
t.
yi Co
Cop py
♦ Vehicles with dual-clutch gearbox ⇒ 6-speed dual-clutch gear‐ ht. rig
rig ht
by
box; Rep. gr. 34 ; Removing and installing gearbox; Remove copy Vo
by lksw
gearbox . cted agen
Prote AG.
– Remove flywheel ⇒ page 67 .

– Remove intermediate plate ⇒ Item 7 (page 66) .

– Turn crankshaft to TDC No. 1 cylinder as shown.

Note
♦ For reasons of clarity, the work is performed with the engine

removed.
♦ The procedure is identical whether the engine is installed or
removed.
– Remove engine speed sender - G28- -arrow- ⇒ page 358 .
– Unscrew mounting bolts -1- to -6- on the sealing flange.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using 3 M6 x 35 mm bolts. lks AG. Vo wagen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
– Screw in 3 M6 x 35 mm bolts into threaded holes of sealing

erm
ab
flange -arrows-.
ility
ot p
wit
, is n
– Screw bolts (max. 180° per bolt) into sealing flange alternately
h re
in order to press it and the sender wheel of crankshaft togeth‐

hole
spec
er.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

CC 2012 ➤ , Golf Cabriolet 2012 ➤ agen
AG. Volkswagen AG d
oes
ksw not
by generation
Vol
II) - Edition 09.2013 gu
a
ed ran
oris tee
2.3.2 Pressing in sealing flange with sender
th or
au ac
ss
wheel
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
♦ The sealing flange with a PTFE seal is provided with a sealing
hole
spec
lip support ring. This support ring serves as a fitting sleeve and
es, in part or in w
must not be removed prior to installation.
t to the co
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
rrectness of i
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
l purpos
♦ Sealing flange and oil seal form one unit and must only be
nform
ercia
renewed together with the sender wheel.

m
♦ The assembly device - T10134- is held in its position relative
at
om
io
to the crankshaft by a guide pin inserted into a hole in the
n
c
in t
crankshaft.
or
his
ate
do
priv
c
Assembly tool - T10134-
um
for
en
ng
t.
yi
A - Clamping surface
Co
Cop py
t. rig
B - Hexagon nut
gh ht
pyri by
Vo
co lksw
by
C - Assembly housing cted agen
Prote AG.
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
1) Mount seal with sender wheel on assembly tool - T10134- .
– Screw on hexagon nut -B- until just before it touches the

clamping surface -A- of the threaded spindle.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press the assembly housing -C- downwards until it lies on
hexagon nut -B-, -arrow-.
– Screw hexagon nut onto threaded spindle until inner part of
assembly device and assembly housing are at same height.

– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
twisted.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Place sealing flange with front side facing down on a clean
level surface.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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– Push sealing lip support ring -A- downwards in direction of ar‐
h re
hole
row until it lies on flat surface.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Upper edge of sender wheel and front edge of sealing flange
s
iva
do
must align -arrows-.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Place sealing flange with front side facing downwards onto

assembly tool - T10134- so that locating pin -B- can be inser‐
ted in sender wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2) Mount assembly tool - T10134- with sealing flange on crank‐

shaft flange.
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder. agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
d
– Screw hexagon nut -B- on until it reachesoris end of threaded
e nte
eo
spindle. aut
h
ra
ss c
– Press threaded spindle of assembly tool - T10134- in direction
ce
le
un
pt
of arrow, until hexagon nut -B- lies against assembly housing

an
d
itte
-A-.
y li
rm
ab
pe
ility
– Align flat side of assembly housing to crankcase's sealing sur‐

ot
wit
face on the oil sump side.

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Secure assembly tool - T10134- to crankshaft flange with hex‐

l purpos
agon socket head bolts -A-.

nform
ercia
Note
m
a
com
tio
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
n in
r
prox. 5 full turns).

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– To guide sealing flange into cylinder block, screw in 2 M7 ×

35 mm bolts -A-.
3) Bolt assembly tool - T10134- onto crankshaft flange.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Push assembly housing -C- by hand in direction of arrow until
an
d
itte
sealing lip support ring -B- touches crankshaft flange -A-.
y li
rm
ab
pe
ility
– Push guide pin for diesel engines (black knob) -D- into hole in
ot
crankshaft. This ensures that the sender wheel reaches its fi‐
wit
, is n
h re
nal installation position.
hole
spec
es, in part or in w
t to the co
Note
The guide pin for petrol engines (red knob) -F- must not be inser‐
rrectness of i
ted in threaded hole of crankshaft.
l purpos
– Tighten the two hexagon socket head bolts of the assembly

tool hand-tight.
nform
ercia
– Screw hexagon nut -E- onto threaded spindle by hand until it

m
a
com
lies against assembly housing -C-.
tion in
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4) Press sender wheel onto crankshaft flange using assembly tool
thi
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Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
5) Check sender wheel installation position on crankshaft.
– Screw on the hexagon nut -E- until it reaches the end of the
threaded spindle.
– Unscrew 2 bolts -A- from cylinder block.
– Unscrew the three knurled screws -B- out of sealing flange.

– Unscrew the hexagon socket head bolts -A- and remove the
assembly tool - T10134- .
– Remove sealing lip support ring.
lkswage es n
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– The sender wheel is in the or correct installation position on the
is tee
crankshaft if a gap -a-au= 0.5 mm exists between crankshaft
th or
ac
flange -A- and sender wheel -B-.
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– Place caliper gauge on crankshaft flange.
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– Measured distance -a- between crankshaft flange and sender
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wheel.
If dimension -a- is too small:
– Re-press sender wheel ⇒ page 77 .
If dimension -a- is achieved:
– Tighten new sealing flange securing bolts diagonally and al‐
ternately.

– Install engine speed sender - G28- -arrow- ⇒ page 358 .

– Install sump ⇒ page 156 .
– Install intermediate plate ⇒ Item 7 (page 66) .
– Install flywheel with new bolts.
Specified torques
Securing bolts for the sealing flange 15 Nm
♦ Renew.
♦ Tighten alternately and diagonally
Engine speed sender - G28- 5 Nm

Flywheel 60 Nm + 90°
♦ Renew.
Manual gearbox ⇒ 6-speed manual gearbox; Rep. gr. 34 ; Removing and

installing gearbox; Installing gearbox .
Dual-clutch gearbox ⇒ 6-speed double clutch gearbox; Rep. gr. 34 ; Removing
and installing gearbox; Torque settings for gearbox .
Oil sump ⇒ “1 Sump, oil pump”, page 151
6.) Press sender wheel again.

– Secure assembly tool - T10134- to crankshaft flange with hex‐
agon socket head bolts -A-. gen AG
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– Tighten the two hexagon
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– Put on the assemblytho tool - T10134- for the sealing flange by e or
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– Screw hexagon nut -E- onto threaded spindle by hand until it

lies against assembly housing -C-.
rrectness o
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agen 2. Cylinder block, gearbox end
– Tighten the hexagon nut of assembly tool - T10134- with tor‐

que wrench - V.A.G 1331- and tool insert to 40 Nm - V.A.G
1332/11- .
– Check sender wheel installation position on the crankshaft
⇒ page 75 .
If dimension -a- is too small again:
– Tighten hexagon nut for the assembly tool - T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
⇒ page 75 .
AG. Volkswagen AG d
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3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 79
⇒ “3.2 Renewing needle bearing in crankshaft”, page 80
⇒ “3.3 Crankshaft dimensions”, page 81
3.1 Assembly overview - crankshaft
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
1 - Bearing shell
❑ For bearings 1, 2, 4 and
5.
❑ Do not interchange
used bearing shells
(mark).
❑ Renew.
❑ To measure radial clear‐
ance, tighten to 65 Nm AG. Volkswagen AG d
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3 - Bearing cap rise
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❑ Bearing cap 1: belt pul‐ s au ra
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❑ Bearing cap 3 with re‐
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4 - Thrust washer
❑ For bearing cap 3.
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❑ Note fixing arrange‐

ment.
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5 - Needle bearing
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❑ Only vehicles with dual-

or
clutch gearbox.
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c
⇒ page 80
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6 - Crankshaft
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❑ Axial clearance new:

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❑ New: 0.03…0.08 mm, wear limit: 0.17 mm.
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❑ Do not rotate crankshaft when checking radial clearance.

❑ Crankshaft dimensions ⇒ page 81 .
3. Crankshaft 79
7 - Thrust washer
❑ For cylinder block, bearingw3.
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3.2 Renewing needle bearing in crankshaft
t
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Vehicles with dual-clutch gearbox only.

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♦ With adapter - T10055/3-
or
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♦ Centring mandrel - 3176-

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♦ or drift - VW 207 C-
♦ Puller, e.g. Kukko - 21/2-
Note
Vehicles with dual-clutch gearbox, the needle bearing must be

installed in rear end of crankshaft.
Removing
– Pull out using commercially available puller, e.g. Kukko 21/2
-arrow-, adapter - T10055/3- and puller - T10055- .
Installing
Note
The lettering on the needle bearing must be visible when installed.

– Drive in with drift - VW 207 C- or centring mandrel - 3176- .
AG. Volkswagen AG d
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Installation depth: dimension -a- = 2 mm.
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3.3 Crankshaft dimensions

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(Dimensions in mm)
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Basic dimension 54.00 -0.022 50.90 -0.022
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3. Crankshaft 81
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 82
⇒ “4.2 Measuring piston projection at TDC ”, page 85
⇒ “4.3 Separating new conrod”, page 87
⇒ “4.4 Checking radial clearance of conrods”, page 88
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 83 . AG. Volkswagen AG d
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❑ Checking ring-to-groove olksw not
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clearance ⇒ page 84 . ed b ara
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❑ Top and centre: Com‐ aut
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❑ Bottom: Oil scraper ring.

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2 - Piston
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❑ With combustion cham‐
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❑ Mark installation posi‐
spec
tion and cylinder num‐
ber
t to the co
❑ Installation position and
allocation of piston to
rrectne
cylinder ⇒ page 85 .
❑ Arrow on piston crown
s
points to belt pulley end
s o
cial p
f
❑ Install using piston ring
inform
clamp
mer
❑ If piston skirt is cracked,

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❑ Checking piston projec‐

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tion at TDC
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⇒ page 85
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3 - Piston pin
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❑ Remove and install using drift - VW 222- . Prote AG.
4 - Circlip
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen
❑ Installation position: Marking -B- faces towards pulley end
❑ With industrially cracked conrod cap
❑ Separate new conrod ⇒ page 87
6 - Bearing shell
❑ Note installation position ⇒ page 85

❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑ Do not rotate crankshaft when checking radial clearance
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 84 .
❑ Piston and cylinder dimensions ⇒ page 85 .
8 - Conrod bearing cap
❑ Note installation position.
❑ Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the caps
only fit in one position and only on the associated conrod
9 - Oil spray jet
❑ For piston cooling.
10 - 25 Nm
❑ Insert without sealant
11 - Conrod bolt, 30 Nm + 90° further
❑ Renew. lkswage es n
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❑ Oil threads and contact surface ir se
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❑ Use old bolt for measuring radial clearance
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Checking piston ring gap
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♦ Feeler gauges
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– Insert piston ring at right angles from above and push down
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Piston ring New Wear limit

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dimensions in mm (mm) (mm)
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1st compression ring 0.20 … 0.40 1.00
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2nd compression ring 0.20 … 0.40 1.00
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Prote AG.
Oil scraper ring 0.25 … 0.50 1.00
4. Pistons and conrods 83

Checking ring-to-groove clearance

♦ Feeler gauges
– Clean annular groove before check.
Piston ring New Wear limit agen
AG. Volkswagen AG d
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1st compression ring 0.06 … 0.09 0.25 horis nte
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2nd compression ring 0.05 … 0.08 0.25
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Oil scraper ring 0.03 … 0.06 0.15

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Checking cylinder bores
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♦ Internal dial test indicator 50 - 100 mm
lksw
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Prote AG.
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
• Difference between actual and nominal diameter max. 0.10
mm.

Note
Cylinder bores must not be measured when the cylinder block is

secured to engine and gearbox support - VAS 6095- , as meas‐
urements may be incorrect.
Checking piston
– Using a micrometer (75 - 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm
Nominal dimension ⇒ page 85
Note
Piston must be changed if piston shaft reveals cracking.

AG. Volkswagen AG d
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Installation position and allocation of pistonsetod bcylinder
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Arrow on piston crown -arrows- points ain ut direction of Cylinder 1.
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Big-end bearing shells mounting position
Bearing shell -1- with oil hole -arrow- for conrod.
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Bearing shell -2- without oil hole for conrod bearing cap.
cial p
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– Position bearing shells in centre of conrod and conrod bearing
mer
cap when fitting.

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Dimension -a- must be identical on both sides.

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4.1.1 Piston and cylinder dimensions
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Honing dimension Piston diameter Cylinder bore diam‐

(mm) eter
(mm)
Basic dimension 80.96 1) 81.01
• 1)Dimensions include coating (thickness 0.02 mm). The
coating will wear down.
4.2 Measuring piston projection at TDC


equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool - VW 382-
♦ Measuring plate -
VW 385/17- from universal
measuring tool - VW 385-
♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
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Test procedure ut
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– Secure dial gauge - VAS 6079- with measuring bridge - s
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VW 382/7- and measuring plate -VW 385/17- to cylinder block

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as shown in the illustration.

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Rep. gr.13 - Crankshaft group Prote
cted AG.
agen
– Measure the projection of each piston at the two points marked

with -arrows- (at the rear side and front side of the piston seen
in the longitudinal direction of the engine).
Piston projection at TDC must be measured when new pistons or
a short engine is installed. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Note
♦ To measure the piston projection at top dead centre, turn

agen the
AG. Volkswagen AG d
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♦ If different values are determined during the
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urement, use the largest dimension fors aselecting
ut
the gasket. or
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Piston projection Identification
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Holes/notches
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0.91 - 1.00 mm 1
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1.11 - 1.20 mm 3
spec
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4.2.1 Cylinder head gasket identification
♦ Part no. = arrow 1
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♦ Holes = arrow 2
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♦ Production control code = arrow 3 (can be disregarded)
nf
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♦ Different thicknesses of cylinder head gasket are fitted de‐
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pending on the piston projection. When the seal is renewed,

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ensure that the designation matches.
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♦ Piston projection at TDC must be determined when installing
Co
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new pistons or a short engine ⇒ page 85 .
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4.3 Separating new conrod

On new conrods, it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap cannot
be removed by hand:
– Mark allocation of conrod to cylinder.

– Lightly clamp the conrod in a vice using aluminium vice

clamps, as shown in the illustration.
Note
♦ Only clamp the conrod lightly in order to avoid damaging it.

♦ Conrod is clamped below the dashed line.
– Unscrew both bolts -arrows- about 5 turns.

AG. Volkswagen AG d
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– Using a plastic horihammer,
s carefully knock against conrod bear‐
nte
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ing cap in -direction
s aut of arrow- until it is loose. ra
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4.4 Checking radial clearance of conrods
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♦ Plastigage
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Procedure
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– Remove conrod bearing cap. Clean bearing cap and bearing

thi
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– Place a Plastigage corresponding to the width of the bearing

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on the journal or into the bearing shells. Cop
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– Fit conrod bearing cap and tighten to 30 Nm without further rig ht
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turning angle and without rotating crankshaft. co Vo
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– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• Wear limit: 0.08 mm
– Renew conrod bolts.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 89
⇒ “1.2 Removing and installing cylinder head”, page 91
wage es n
⇒ “1.3 Assembly overview - cylinder head cover”, ypage Volks 99 ot g
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⇒ “1.4 Removing and installing cylinder head horcover”, page 101
is tee
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⇒ “1.5 Removing and installing vacuum pump”,
ss page 104
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⇒ “1.6 Checking compression”, page 105
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1.1 Assembly overview - cylinder head
ab
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1 - Cylinder head gasket
hole
spec
❑ Renew.
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t to the co
❑ Cylinder head gasket
identification
⇒ page 91 .
rrectness of i
❑ Renew coolant and en‐
l purpos
gine oil after replacing.

2 - 10 Nm
nform
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❑ Insert with locking fluid,

locking fluid ⇒ Electron‐
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ic Parts Catalogue (ET‐
on
c
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3 - Hall sender - G40-
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❑ For camshaft position

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⇒ page 357
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4 - Cylinder head
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⇒ page 91
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
❑ Check for distortion
⇒ page 90 .
❑ Must not be reworked.
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head on cylinder
block are fitted.
❑ Renew coolant and en‐
gine oil after replacing.
5 - Washer
6 - Cylinder head bolt
❑ Renew.
❑ Sequence when loosening ⇒ page 90 .
1. Cylinder head 89
7 - Oil pressure switch - F1- , 20 Nm

❑ Switch pressure 0.3 - 0.6 bar.
❑ Checking ⇒ page 173 .
8 - Seal
❑ Renew.
9 - 20 Nm
10 - Engine lifting eye AG. Volkswagen AG d
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11 - Seal d b ara
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❑ Renew. autho eo
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12 - 20 Nm
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13 - Gasket
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❑ Renew.
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15 - 10 Nm
t to the co
16 - Connection
❑ For coolant hoses
rrectness of i
❑ With coolant temperature sender - G62- .
l purpos
17 - 9 Nm
18 - Gasket
nform
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❑ Renew.
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19 - 20 Nm
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20 - Engine lifting eye

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Observe sequence when loosening cylinder head bolts. t. Cop py
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– Slacken the cylinder head bolts in the sequence -1- to -10-. p by
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Prote AG.
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure cylinder head
for distortion at several points.
• Max. permissible distortion: 0.1 mm.
Note
Cylinder heads for TDI engines must not be reworked.
90 Rep. gr.15 - Cylinder head, valve gear

Cylinder head gasket identification

1- Part number
2- Holes
3- Ignore
Note
Different thicknesses of cylinder head gasket are fitted depending

on the piston projection. If only cylinder head gasket is removed,
install a new cylinder head gasket with same identification.
Cylinder head - specified torque and sequence
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– Tighten bolts in 4 stages inssthe sequence shown:
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Stage Bolts Specified torque/turning fur‐
an
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1 -1- to -10- 30 Nm
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2 -1- to -10- 50 Nm
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3 -1- to -10- Turn 90° further spec

4 -1- to -10- Turn 90° further

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1.2 Removing and installing cylinder head

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1. Cylinder head 91

equipment required
♦ Guide pins - 3070-
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Crankshaft stop - T10050-
♦ Counterhold tool - T10051-
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
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1331-
1332-
♦ Drip tray for workshop hoist
- VAS 6208-
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Note
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♦ Read anti-theft radio code as the next work step requires the
s
earth strap of the battery to be disconnected.

s o
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♦ All cable ties which are opened or cut through when cylinder
nform
head is removed must be renewed/replaced in the same po‐

mer
sition when the cylinder head is installed.

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restored.
hot components.
1. Cylinder head 93
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Removing ss
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– With ignition switched off, disconnect earth strap from battery.
un
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⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
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connecting battery
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spec
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
t to the co
27 ; Battery; Removing and installing battery .
– Remove radiator cowl with radiator fan - V7- and remove ra‐
diator fan right - V35- ⇒ page 223
rrectne
– Remove connecting hose on »cold side«
s
⇒ Item 13 (page 239) of charge air cooler.
s o
cial p
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– Remove cylinder head ⇒ page 101 .
nform
mer
– Pull off connector from throttle valve control element - J338-
atio
m
-2-.
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– Unscrew bolt from oil dipstick connection -4-.
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– Pull vacuum pipe off the vacuum pump.

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– Unscrew bolts -2, 5- and -arrows-.

– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
– Loosen hose clip -3- and remove left air pipe.

– Unscrew bolts -arrows- and remove pulsation damper -2-.

sulation .
– Disconnect electrical connector -4- at coolant temperature
sender - G62- .
– Pull coolant hoses off connection. To do this, loosen hose

clamps -1- and -2-.
– Detach connector -1- from oil pressure switch - F1- .

– Remove bolt -arrow-.
– Pull off vacuum hose -2-.
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– Remove electrical connector -3- from bracket and disconnect.

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– Free electrical lines on turbocharger.

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1. Cylinder head
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– Undo and remove securing bolts -arrows- from charge-air pipe

and detach connector from charge pressure sender - G31-
-1-.
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– Open clip -2-, clear away coolant hose -3- and remove charge
spec
air pipe.
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Caution
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Ensure that decoupling element of connecting pipe is not bent
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nform
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– Remove connecting pipes -A- for exhaust gas recirculation

using bit - T10385- .

– Unscrew securing nuts -arrows- of particulate filter bracket

-A- on crankcase. wage
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– Undo union nuts -2- and remove bolt -3-.
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– Unscrew bolt -arrow- on the rear toothed-belt guard. t. Cop py
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– Loosen connecting clamp between turbocharger and particu‐ pyri by
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– Unscrew securing bolt of bracket on cylinder head -arrow- and

push particulate filter to one side.
1. Cylinder head 97
– Detach connector for Hall sender - G40- -arrow-.

– Remove toothed belt from camshaft ⇒ page 110 .
– Remove toothed belt pulley of camshaft and pull off camshaft
hub using puller - T10052- .
– Unscrew securing nut of toothed belt tensioning roller.
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– Loosen cylinder head bolts in sequence -1 to 10-. nl
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Note
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♦ A second mechanic is required for the removal of the cylinder
hole
head.
spec
es, in part or in w
t to the co
♦ The toothed belt tensioning roller is pulled off the stud when
the cylinder head is lifted out.
♦ The oil return line of the turbocharger is pulled out of the sup‐
rrectness of i
port when the cylinder head is lifted out.
l purpos
– Lift up cylinder head on gearbox side first and guide out of

toothed belt guard. Make sure that toothed belt tensioner does
nf
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not fall down.
rm
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– Place cylinder head down in such a way that oil return line does
o
n in
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not become bent. If necessary, place piece of wood under ex‐

or
thi
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haust manifold.
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♦ Always renew cylinder head bolts.
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♦ In cases of repair, carefully remove gasket remains from cyl‐

inder head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
paper do not use a grade less than 100.
♦ Carefully remove emery and abrasive remains.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Before fitting cylinder head, remove crankshaft stop - T10050-

and turn crankshaft opposite direction of rotation until all pis‐
tons are nearly uniformly below TDC.
– Cylinder head gasket must lie with identification facing up‐
wards.

– To centre, screw guide pins - 3070- into outer threaded holes

on intake side.
Note
Tensioning roller must be pushed onto studs when fitting cylinder

head.
– Fit cylinder head, install 8 cylinder head bolts and hand-tight‐

en.
– Remove guide pins through bolt holes using removal tool from
3070 and install cylinder head bolts.
– Tighten cylinder head in 4 stages in sequence shown as fol‐

lows:
1- Tighten initially with torque wrench:
Stage I = 30 Nm
Stage II = 50 Nm
2- Turn further with rigid spanner:
Stage III = 90°
Stage IV = 90°
– Fasten rear toothed-belt guard on cylinder head.
– Install hub and camshaft sprocket.
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– Turn
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lock the crankshaft with the crankshaft stop - T10050- .
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– Fit toothed belt ⇒ page 110 .

d
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Further installation is carried out in the reverse order. In the proc‐

ility
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wit
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– Install cylinder head cover ⇒ page 101 .

ole,
spec
– Install poly V-belt ⇒ page 42 .

t to the co
– Replenish coolant ⇒ page 189 .

– Carry out road test and read all event memories ⇒ Vehicle
rrectne
diagnostic tester .
ss
1.3 Assembly overview - cylinder head cov‐

o
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f in
er
form
mer
atio
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⇒ “1.4.1 Renewing seals for injectors”, page 103

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When installing a new short engine, it is compulsory to fix and

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tighten the clamping jaws of the injectors with the specified
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torque after installing the high-pressure lines ⇒ page 251 .
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injectors while installing high-pressure lines. Non-observance
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of these notes may lead to damage to engine.
1. Cylinder head 99
1 - Gasket
❑ Renew if damaged or
leaking.
2 - Cylinder head cover AG. Volkswagen AG d
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3 - O-ring ss a ra
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❑ For crankcase ventila‐
ility
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❑ Press release buttons to
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spec
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5 - Sealing bushing
❑ For high-pressure accu‐
mulator (fuel rail).
rrectness of i
❑ Renew if damaged or
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leaking.
6 - Bracket
nform
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❑ For electrical cables.

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7 - Grommet
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8 - Clamping piece
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9 - 8 Nm
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10 - High-pressure accumula‐
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❑ Do not attempt to re‐
AG.
shape high-pressure
lines.
❑ Installing high-pressure
lines ⇒ page 263 .
11 - 22 Nm
❑ Renew.
13 - Fuel return line
14 - O-ring
❑ Renew.
15 - Injector
❑ Observe rules for cleanliness ⇒ page 6 .
16 - O-ring
❑ Renew.
17 - Heat shield seal
❑ Renew.
18 - Seal
❑ For injector.

19 - Cap
20 - Gasket
❑ For cap.
21 - Grommet
22 - Bracket
23 - Bolt
❑ Renew seal if damaged.
Cylinder head cover - tightening torque and sequence AG. Volkswagen AG d

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– Tighten bolts for cylinder head cover in the sequence
ed b -1- to ara
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1.4 Removing and installing cylinder head
rrectness of i
cover
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Removing
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– Disconnect electrical connector -2- at pressure differential

m
at
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sender - G505- .
ion
c
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– Unscrew bolt -3-, pull pressure differential sender - G505- from

his
ate
bracket -arrow- and lay aside. do

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– Release clips -arrows- and press upper toothed belt guard

aside to the right.
– Removing high-pressure accumulator (rail) ⇒ page 251 .
1. Cylinder head 101

– Remove crankcase breather hose -1- from cylinder head cov‐

er; press release buttons for this.
– Disconnect electrical connector -arrow- at position sender for

charge pressure positioner
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– Remove vacuum
ris lines from bracket on cylinder head cover.
ed ran
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– Release and unscrew bolts for cylinder head cover in the se‐
quence -6- to -1-.
rrectne
– Remove cylinder head cover.

Installing
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atio
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Note
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♦ Renew gasket for cylinder head cover and bolts for cylinder
iv
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head cover if damaged or leaking.

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♦ Renew grommets and seals for injectors if damaged or leak‐
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– Slacken bolts for cylinder head cover in the sequence
AG.
-1- to -6-.

– Ensure that cylinder head cover is correctly clipped to toothed

belt guard, -arrows-.
Note
For reasons of clarity, diagram shows installation position with

camshaft sprocket removed.
– Check clearance between hub and toothed belt guard.

Volkswa
– Installing high-pressure
agenaccumulator (rail)
AG. gen AG
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⇒ page 251 . by V ol ot g
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– Install pressure
tho
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or
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Specified torque
hole
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es, in part or in w
t to the co
Bolts for cylinder head cover 9 Nm
rrectness of i
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1.4.1 Renewing seals for injectors

nform

mercia
♦ Follower - 3390-
at
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ion
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or
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ate
do
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Procedure
– Remove cylinder head cover ⇒ page 101 .
– Press out seal for injector using carrier - 3390- and short ex‐
tension -1- from bottom to top.

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4-cylinder diesel engine (2.0 l engine, gen AG
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– Press in new seal for injector using
ho
ris carrier - 3390- and short tee
extension -1- from top to stop.aut or
ac
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t to the co
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1.5 Removing and installing vacuum pump
ss o
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DANGER!
nform
mer
atio
The vacuum pump may, under no circumstances, be disman‐
om
n
tled as the vacuum part could otherwise malfunction. This
c
i
or
n
would result in the failure of the brake booster.
thi
te
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Removing
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– Pull vacuum line -2- off vacuum pump -1-. by c lksw
cted agen
Prote AG.
– Remove crankcase breather connecting pipe-1- from cylinder

head cover; press release buttons to do this.
– Unclip and remove plug on the crankcase ventilation hose
-1-.
– Free vacuum hoses -arrows-.
– Unscrew bolt -2- (captive), swing air pipe with inlet pipe to rear
and pull off from turbocharger.
– Seal opening in turbocharger with sealing cap from engine
bung set - VAS 6122- .

– Remove securing bolts -4 to 1-.

– Remove vacuum pump -A- from cylinder head.
Installing
Note
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♦ Ensure that by V vacuum pump coupling seats properly
o l ot g
ua in the cam‐
shaft. o
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th or
♦ The
ss
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ce
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un
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– Install vacuum pump -A- and screw on the bolts loosely.
y li
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ab
ility
– Connect brake booster vacuum line to the connection to the
ot p
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vacuum pump -A-.
is n
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mer
Tightening sequence
atio
m
– Tighten the vacuum pump -A- in the sequence -1- to -4-.

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Specified torque
Securing bolt for the vacuum pump 10 Nm
1.6 Checking compression


AG. Volkswagen
CC 2012 ➤ , Golf Cabriolet 2012 ➤ ksw
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♦ Jointed spanner - 3220- au ra
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♦ Compression tester - V.A.G 1763- with adapter - V.A.G

1763/8-
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♦ Torque wrench (5…50 Nm) - V.A.G 1331-

Test prerequisite
• Engine oil temperature min. 30°C.
Test procedure
– Pull connectors off the injectors.
– Remove sheathed glow plugs using U/J extension and socket
- 3220- ⇒ page 355 .
– Screw in adapter - V.A.G 1763/8- in place of the glow plugs.
– Check compression using compression tester - V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions
– Start engine until tester shows no further pressure increase.

Compression pressures:
New: 25…31 bar.
Wear limit: 19 bar.
Maximum permissible difference between all cylinders: 5 bar
– Install glow plugs with the U/J extension and 10 mm socket -
3220- ⇒ page 355 .
– Read engine control unit event memory ⇒ Vehicle diagnostic
tester .

Note
Events will have been stored in the event memory because the
connectors for injectors have been disconnected. Therefore, read
event memory and delete if necessary.
AG. Volkswagen AG d
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a
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tion in
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2 Toothed belt drive

⇒ “2.1 Assembly overview – toothed belt”, page 108
⇒ “2.2 Removing and installing toothed belt”, page 110
2.1 Assembly overview – toothed belt
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 110 .
2 - Bolt
❑ Renew after removing
❑ Specified torque
⇒ Item 1 (page 60) .
3 - Crankshaft pulley
4 - 20 Nm
5 - Guide roller
7 - Tensioning roller
❑ Note different versions
⇒ page 111
❑ Remove engine bracket
in order to remove and
install ⇒ page 52 . n AG. Volkswagen AG do
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8 - 20 Nm + turn 45° further d b ua
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9 - Camshaft pulley aut or
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10 - 20 Nm
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11 - 100 Nm
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erm
ab
12 - Hub
ility
ot p
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❑ Use counterhold tool -

h re
T10051- to loosen and

ole,
spec
tighten.
t to the co
❑ To remove, use puller - T10052- .

rrectne
13 - Rear toothed belt guard

❑ Observe proper seating of cylinder head cover ⇒ page 102
ss
14 - 20 Nm
o
cial p
f inform
15 - 10 Nm
mer
❑ Renew.
atio
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n
c
16 - Guide roller
i
or
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❑ Renew.
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18 - Hub Cop py
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gh
❑ Use counterhold tool - T10051- to loosen and tighten.
ht
pyri by
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by
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Prote AG.

❑ To remove, use puller - T40064- .
19 - 95 Nm
20 - Toothed belt pulley on high-pressure pump
21 - 20 Nm
22 - Coolant pump
23 - 15 Nm
24 - Toothed belt guard upper part AG. Volkswagen AG d
agen oes
olksw not
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25 - Toothed belt guard lower part ed b ara
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ris
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26 - Toothed belt guard centre part aut ra
c
ss
27 - 10 Nm
ce
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nl
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❑ Renew.
itte
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ab
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❑ Renew.
, is n
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29 - Belt pulley and vibration damper
spec
es, in part or in w
❑ Assembly through offset holes only possible in one position.
t to the co
30 - 5 Nm
31 - Protective plate
rrectness of i
l purpos
❑ Renew.
❑ Observe tightening sequence ⇒ page 52 .
nform
ercia
33 - Engine bracket
m
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or
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ate
do
priv
cum
for
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
2. Toothed belt drive 109

2.2 Removing and installing toothed belt

equipment required
♦ Locking pin - 3359-
♦ Angled screwdriver -
T10264- for tensioning roll‐
er A
♦ Locking tool - T10265-
AG. Volkswagen AG d
agen oes
olksw not
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♦ Angle driver, 8 mm - T10409- for tensioning roller B

rm
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nform
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Not illustrated
com
tion in

r
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s
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Cop py
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110
by c lksw
cted
Rep. gr.15 - Cylinder head, valve gear
agen
Prote AG.
Note
2 versions of tensioning roller are fitted. They are not interchange‐

able. When performing adjusting measures, check first to see
which tensioning roller is installed.
Observe different directions of rotation during tensioning

Features tensioning roller A
♦ Locking tool - T10265- required for installation.
♦ Check tensioning roller is seated correctly in timing belt guard
⇒ page 116
♦ Tension toothed belt by turning tensioning roller eccentric
»clockwise«
Features tensioning roller B
♦ Locking tool not required.
♦ Tensioning roller is not seated in timing belt.
♦ Tension toothed belt by turning tensioning roller eccentric
»counter clockwise«
⇒ “2.2.1 Removing and installing toothed belt, tensioning roller A”,
page 111
⇒ “2.2.2 Removing and installingntoothed
AG. Volksbelt,
wagen tensioning
AG do
roller B”,
page 119 olkswage es n
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2.2.1 Removing and installing toothed belt,
aut
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Removing
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Note
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ole,
spec
The toothed belt may only be adjusted on cold engines, as the

indicator position on the tensioning element varies depending on

t to the co
the engine temperature.

rrectne
Caution
ss
Risk of irreparable damage if direction of rotation is reversed

o
cial p
on previously used toothed belt.

inform
mer
♦ Before removing toothed belt, mark direction of rotation

atio
m
with chalk or felt tipped pen for installation purposes.

o
n
c
i
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te
sd
va

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fo
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t.
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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐ Cop py
. rig
sulation .
t
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pyri by
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cted agen
Prote AG.


– Release and unplug electrical connector from coolant expan‐
sion tank -2-.
– Place coolant expansion tank -2- to one side.
WARNING

low the fuel to cool down before disconnecting the lines -
danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.
– Open push-on couplings -A- and -B- of fuel lines and pull fuel
lines off. Disconnect push-on couplings ⇒ Rep. gr. 20 ; Dis‐
connecting push-on couplings .
G. Volkswagen AG d
– Remove fuel filter and lay it to one side ⇒ Rep. lksw
gr.
agen20 ; Fuel
A
oes
not
filter; Removing and installing fuel filter .d by Vo gu
ara
e nte
ris
Golf Cabriolet: tho eo
s au ra
c
– Remove supplementary fuel pump s - V393- or fuel pump 2 -
ce
e
nl
pt
du
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itte
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erm
ab
ility
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wit
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spec
es, in part or in w
-2-.
t to the co
– Unscrew securing bolts -1-.
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

olkswagen AG
en AG. V
– Remove toothedolkbelt
swa guard, opening clips
g doe-arrows-
s no to do so.
V t gu
by a
– Remove frontris
ed right wheel housing liner: ⇒ General ranbody re‐
tee
pairs, aexterior;
utho
Rep. gr. 66 ; Wheel housing liner; Removing
or
ac
and installing
ss wheel housing liner .
ce
e
nl
pt
du
an
itte
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– Remove vibration damper ⇒ Item 29 (page 109) .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove centre and lower toothed belt guards -arrows-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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gh
– Turn engine to TDC and lock crankshaft sprocket in position
ht
pyri by
Vo
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with crankshaft stop - T10050- . by c lksw
cted agen
Prote AG.
– To do so, push crankshaft stop from face side of sprocket onto
teeth of crankshaft sprocket -2-. Toothed segment must be at
»12 o'clock position«.
Note
The markings on the crankshaft pulley -2- and the crankshaft stop
- T10050- -1- must align.
– Pin of crankshaft stop - T10050- must engage in bore

-arrow- in sealing flange.
– Mark direction of rotation of toothed belt.

– Loosen securing bolts -1- of camshaft pulley.
– Loosen securing bolts of sprocket of high-pressure pump -2-.
AG. Volkswagen AG d
agen oes
olksw not
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un
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ab
ility
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– Loosen belt tensioner securing nut -1-.
h re
ole,
– Turn eccentric of tensioning roller anti-clockwise -arrow- using

spec
socket - T10264- , until the tensioning roller can be locked with

locking tool - T10265- . t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

n AG. gen AG Volkswa
wage
– Turn the tensioning roller eccentricVclockwise -arrow- onto does not
olks
stop and tighten securing nut -1-
ed hand-tight.
by gu
ara
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– Remove toothed belt first from
au
th idler pulley and then from re‐ eo
ra
maining toothed pulleys.ss c
ce
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nl
pt
Installing
du
an
itte
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ab
ility
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Note
wit
, is n
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hole
♦ The toothed belt may only be adjusted on cold engines, as the
spec
indicator position on the tensioning element varies depending
es, in part or in w
t to the co
on the engine temperature.
♦ If the tensioning roller is to be renewed, the engine bracket
must be removed ⇒ page 52 .
rrectness of i
♦ Renew securing bolts for camshaft pulley and high-pressure
l purpos
pump pulley.
♦ 2 versions of tensioning roller are fitted. They are not inter‐
nform
ercia
changeable. When performing adjusting measures, check first

to see which tensioning roller is installed.
m
at
om
ion
c
in t
or
• Tensioning roller must be locked with locking tool - T10265-
his
ate
and secured to right stop.
do
priv
cum
or
• Crankshaft is locked using crankshaft stop - T10050- .

f
en
ng
t.
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Cop py
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Note pyri by
Vo
co lksw
by
cted agen
Prote AG.
Turn camshaft hub with counterhold tool - T10172- and adapters
- T10172/4- until camshaft can be locked in position. To do this,
hand-tighten at least one securing bolt -1-.
– Lock the camshaft hub with locking pin - 3359- . To do this,

insert locking pin through outer free elongated hole into hole
in cylinder head.
– Loosen the hand-tightened bolts again.
Note
If necessary, turn hub of high-pressure pump at bolt heads with

screwdriver until it can be locked in position.

Positioning hub of high-pressure pump
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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push locking pin into adjustment hole outside toothed belt pul‐
nf
ercia
ley.
orm
m
atio
– Turn camshaft sprocket and toothed belt sprocket of high-
om
n in
pressure pump in their elongated holes clockwise to stop.
or c
thi
te
sd
– Fit toothed belt to crankshaft pulley, tensioning roller, cam‐
iva
o
r
shaft pulley, toothed belt pulley of coolant pump and toothed

rp
cu
o
m
belt pulley of high-pressure pump.
f
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ng
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op
– Finally, place toothed belt onto idler pulley. C py
t. rig
gh ht
yri by
– Undo the fastening nuts of the tensioning roller and pull out cop Vo
by lksw
locking tool - T10265- . cted agen
Prote AG.
Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
Seat of tensioning roller in cylinder head

– Carefully turn eccentric of belt tensioner clockwise using angle

driver - T10264- . Indicator -2- must be roughly past the centre
of the gap in the base plate (rectifies itself during pretension‐
ing).
Ensure that securing nut -1- does not turn as well.
. Volkswagen AG
a gen AG d
– Hold tensioningVoroller
lksw in this position and tighten
oes
not securing nut
gu
of tensioning
ed roller.
by ara
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ris tee
utho or
a ac
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
– Fit counterhold - T10172- as shown. Press counterhold tool -
wit
is n
T10172- in direction of arrow and keep camshaft sprocket in
h re
ole,
pretensioned position.
spec
– In this position initially hand-tighten securing bolts of camshaft
t to the co
sprocket and high-pressure pump sprocket.
– Tighten securing bolts to 20 Nm.
rrectne
– Remove locking pins - 3359- and crankshaft stop - T10050- .
s
– Turn crankshaft at least 2 rotations in engine direction of ro‐
s o
tation and set again to TDC no. 1 cylinder.
cial p
f inform
– Place crankshaft stop - T10050- on the crankshaft toothed belt
mer
sprocket again. atio

om
n
c
i
or
n thi
– Turn crankshaft in direction of engine rotation until crankshaft

te
sd
a
stop pin -arrow- engages in sealing flange whilst turning.

iv
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
During the following checking procedure, only the camshaft and

crankshaft must be secured in position. It is very difficult to find
the securing position of the high-pressure pump hub again. How‐
ever, a slight deviation -arrow- does not influence the engine
operation.
– Check whether:
♦ Camshaft hub can be locked with locking pin - 3359- .
♦ Tensioning roller indicator is centred or maximum 5 mm to
right of base plate notch.
If camshaft hub cannot be locked:
– Pull crankshaft stop - T10050- back until pin clears hole.
– Turn crankshaft out slightly past TDC by turning it counter to
direction of engine rotation.
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be secured in position.
– After locking, loosen securing nuts of crankshaft pulley.
If pin of crankshaft stop - T10050- is standing on left next to hole:
AG. Volkswagen AG d
agen
– Turn crankshaft in engine direction of rotation untilolcrankshaft
ksw
oes
not
yV gu
stop pin engages in sealing flange whilst turning.
ed
b ara
nte
is
or eo
– Hand-tighten camshaft sprocket securing
au bolts initially.
th ra
ss c
– Tighten camshaft toothed belt sprocket securing bolts to
ce
e
nl
pt
20 Nm.
du
an
itte
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erm
If pin of crankshaft stop - T10050- is standing on right next to hole:
ab
ility
ot p
– Turn crankshaft a little in direction opposite to engine direction

wit
, is n
of rotation.
h re
hole
– Turn crankshaft in engine direction of rotation until crankshaft spec

es, in part or in w
stop pin arrow engages in sealing flange whilst turning.

t to the co
– Hand-tighten camshaft sprocket securing bolts initially.

rrectness of i

20 Nm.
l purpos
Continuation
nform
ercia
– Remove locking pin - 3359- and crankshaft stop - T10050- .

m

at
om
io

n
c
in t
or
his
e
– Repeat measurement.
at
do
priv
– If camshaft hub can be secured in position, tighten securing

um
for
en
g
bolts as follows:
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Counterhold with counterhold - T10172- and adapters -

T10172/4- .
♦ Tighten securing bolts to 20 Nm.
♦ Camshaft sprocket: 45° further.
♦ High pressure pump sprocket: 90° further.
– Install middle and lower toothed belt guards.
– Install vibration damper/belt pulley.
– Install upper toothed belt guard.
or with blue marking, supply line white).
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
tion .
Specified torques
Tensioning roller agen
AG. Volkswagen AG d
oes 20 Nm +45°
olksw not
Camshaft pulley d by V 20
gu Nm +45°
ara
ise ne
High-pressure pump pulley uthor
20 tNm
eo
a ra
Turning vibration damper/belt pulley further ss 10 Nm + 90° c
ce
le
un
pt
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itte
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erm
ab
2.2.2 Removing and installing toothed belt,

ility
ot p
wit
tensioning roller B
is n
h re
ole,
spec
Removing
t to the co
Note
rrectne
The toothed belt may only be adjusted on cold engines, as the

indicator position on the tensioning element varies depending on
ss
the engine temperature.

o
cial p
f inform
mer
atio
Caution
om
n
c
i
or
Risk of irreparable damage if direction of rotation is reversed

thi
te
sd
a
on previously used toothed belt.

iv
o
pr
cum
r
fo
♦ Before removing toothed belt, mark direction of rotation

en
ng
t.
yi
with chalk or felt tipped pen for installation purposes.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Remove engine cover panel ⇒ page 7 . Prote
cted AG.
agen


sulation .
– Release and unplug electrical connector from coolant expan‐
sion tank -2-.
– Place coolant expansion tank -2- to one side.
WARNING

low the fuel to cool down before disconnecting the lines -
danger of scalding. AG. Volkswagen AG d
agen oes
ksw
♦ Wear protective gloves. byV
ol not
gu
d ara
e nte
♦ Wear eye protection. horis
eo
aut ra
ss c
ce
e
nl
pt
du
an
– Open push-on couplings -A- and -B- of fuel lines and pull fuel
itte
y li
lines off. Disconnect push-on couplings ⇒ Rep. gr. 20 ; Dis‐
erm
ab
ility
connecting push-on couplings .
ot p
wit
, is n
– Remove fuel filter and lay it to one side ⇒ Rep. gr. 20 ; Fuel
h re
hole
filter; Removing and installing fuel filter .
spec
es, in part or in w
Golf Cabriolet:
t to the co
rrectness of i
l purpos
nf
ercia
or
m
m
atio
-2-.
om
n in
or c
– Unscrew securing bolts -1-.
thi
te
sd
iva

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove toothed belt guard, opening clips -arrows- to do so.

– Remove vibration damper ⇒ Item 29 (page 109) .
– Remove centre and lower toothed belt guards -arrows-.
– Turn engine to TDC and lock crankshaft sprocket in position

with crankshaft stop - T10050- .
– To do so, push crankshaft stop from face side of sprocket onto
teeth of crankshaft sprocket -2-. Toothed segment must be at
. Volkswagen AG
»12 o'clock position«. swa
gen AG does
k not
Vol gu
d by ara
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ris
Note utho eo
ra
a c
ss
ce
e
The markings on the crankshaft pulley -2- and the crankshaft stop
nl
pt
du
an
- T10050- -1- must align.

itte
y li
erm
ab
ility
ot p
wit
, is n
– Pin of crankshaft stop - T10050- must engage in bore

h re
hole
-arrow- in sealing flange.

spec
es, in part or in w
– Mark direction of rotation of toothed belt.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Loosen securing bolts -1- of camshaft pulley.
– Loosen securing bolts of sprocket of high-pressure pump -2-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Loosen belt tensioner securing nut -1-.
hole
spec
es, in part or in w
– Use angle driver - T10409- to rotate eccentric -2- of tensioning
t to the co
roller clockwise -arrow- until tensioning roller is relieved of
tension.
rrectness of i
– Hand-tighten securing bolt -1-.
l purpos
– Remove toothed belt first from idler pulley and then from re‐
maining toothed pulleys.
nform
ercia
Installing
m
at
om
ion
Note
c
in t
or
his
ate
do
riv
♦ The toothed belt may only be adjusted on cold engines, as the

p
cum
indicator position on the tensioning element varies depending

for
en
g
on the engine temperature.

n
t.
yi Co
Cop py
♦ If the tensioning roller is to be renewed, the engine bracket
t. rig
gh ht
yri
must be removed ⇒ page 52 .
p by
o Vo
by c lksw
cted agen
♦ Renew securing bolts for camshaft pulley and high-pressure
Prote AG.
pump pulley.
♦ 2 versions of tensioning roller are fitted. They are not inter‐
changeable. When performing adjusting measures, check first
to see which tensioning roller is installed.
• Crankshaft is locked using crankshaft stop - T10050- .
Note
Turn camshaft hub with counterhold tool - T10172- and adapters

- T10172/4- until camshaft can be locked in position. To do this,
hand-tighten at least one securing bolt -1-.


insert locking pin through outer free elongated hole into hole
in cylinder head.
– Loosen the hand-tightened bolts again.
Note
If necessary, turn hub of high-pressure pump at bolt heads with

. Volkswagen AG
screwdriver until it can be locked in
swposition.
agen AG does
olk not
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edb ara
ris nte
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ss
Positioning hub of high-pressure pump
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un
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
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push locking pin into adjustment hole outside toothed belt pul‐
Co
op py
ley.
. C rig
ht ht
rig by
py
– Turn camshaft sprocket and toothed belt sprocket of high-
co Vo
by lksw
cted
pressure pump in their elongated holes clockwise to stop.
agen
Prote AG.
– Fit toothed belt to crankshaft pulley, tensioning roller, cam‐

shaft pulley, toothed belt pulley of coolant pump and toothed
belt pulley of high-pressure pump.
– Finally, place toothed belt onto idler pulley.
– Loosen tensioning roller securing nut.
– Carefully turn eccentric -2- of tensioning roller anticlockwise

-arrow- using angle driver, 8 mm - T10409- . Indicator -4- must
be slightly past entre of gap in base plate -3- (rectifies itself
during pretensioning).
Ensure that securing nut -1- does not turn as well.

Markings on tensioning element and tensioning roller -arrow- are

now almost aligned.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.
– Fit counterhold - T10172- as shown. Press counterhold tool -

T10172- in direction of arrow and keep camshaft sprocket in
pretensioned position.
– In this position initially hand-tighten securing bolts of camshaft
sprocket and high-pressure pump sprocket.
– Tighten securing bolts to 20 Nm.
en AG . Volkswag
– Remove locking pins - 3359- and crankshaft
ksw
agestop
n AG - T10050- . does n
y Vol ot g
– Turn crankshaft at least 2 rotationsed in engine direction of ro‐
b ua
ran
ris
tation and set again to TDC no.
th 1 cylinder.
o tee
or
u ac
sa
– Place crankshaft stop - T10050-
s on the crankshaft toothed belt
ce
e
sprocket again.
nl
pt
du
an
itte
y li
erm
ab
– Turn crankshaft in direction of engine rotation until crankshaft
ility
ot p
stop pin -arrow- engages in sealing flange whilst turning.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
During the following checking procedure, only the camshaft and

crankshaft must be secured in position. It is very ndifficult
AG. Volkto
swafind
gen AG
the securing position of the high-pressure opumplksw hub again. How‐
age does
not
ever, a slight deviation -arrow- does notd byinfluence the engine
V gu
ara
operation. or
ise nte
e
th or
au ac
ss
– Check whether:
ce
le
un
pt
an
♦ Camshaft hub can be locked with locking pin - 3359- .
d
itte
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rm
ab
♦ Tensioning roller indicator is centred or maximum 5 mm to
pe
ility
right of base plate notch.
ot
wit
, is n
h re
If camshaft hub cannot be locked:
hole
spec
– Pull crankshaft stop - T10050- back until pin clears hole.
es, in part or in w
t to the co
– Turn crankshaft out slightly past TDC by turning it counter to
direction of engine rotation.
rrectness of i
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be secured in position.
l purpos
– After locking camshaft sprocket, loosen securing nuts.
nform
ercia
If pin of crankshaft stop - T10050- is standing on left next to hole:

m
a
com
tio
– Turn crankshaft in engine direction of rotation until crankshaft
n in
r
te o
stop pin engages in sealing flange whilst turning.
thi
s
iva
do
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rp
cum
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en
g

n
t.
yi Co
20 Nm. Cop py
t. rig
gh ht
yri
If pin of crankshaft stop - T10050- is standing on right next to hole: p by
co Vo
by lksw
cted agen
– Turn crankshaft a little in direction opposite to engine direction Prote AG.
of rotation.
– Turn crankshaft in engine direction of rotation until crankshaft
stop pin arrow engages in sealing flange whilst turning.
20 Nm.
Continuation
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Repeat measurement.
If camshaft hub can be secured in position, tighten securing bolts
as follows:

♦ Counterhold with counterhold - T10172- and adapters -

T10172/4- .
♦ Then tighten securing bolts to 20 Nm.
♦ Camshaft sprocket: 45° further.
♦ High pressure pump sprocket: 90° further.
– Install middle and lower toothed belt guards.
– Install vibration damper/belt pulley.
– Install upper toothed belt guard.
or with blue marking, supply line white).
– Install front right wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
tion .
Specified torques
Tensioning roller 20 Nm +45°
AG. Volkswagen AG d
Camshaft sprocket swagen 20
oes Nm +45°
k not
Vol gu
by
High-pressure pump pulley rised 20 Nmara
nte
ho e
Turning vibration damper/belt pulley further
au
t 10 Nm + 90° or ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 127
⇒ “3.2 Measuring axial play of camshaft”, page 129
⇒ “3.3 Measuring radial play of camshaft”, page 130
⇒ “3.4 Removing and installing camshaft oil seal”, page 130
⇒ “3.5 Removing and installing camshaft”, page 134
⇒ “3.6 Checking hydraulic compensation elements”, page 141
⇒ “3.7 Removing and installing valve stem seals”, page 142
3.1 Assembly overview - valve gear
Caution
Avoid damage to valves and piston crowns after working on

valve gear.
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations toe ensure
that none of the valves make contact AG. Volkthe
gen when
swag
starter
n AG d
is
wa oes
operated. Volks not
gu
by a
ed ran
ris tee
tho or
au ac
ss
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nl
Note
pt
du
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itte
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erm
ab
Cylinder heads with cracks between the valve seats may continue
ility
ot p
to be used without reducing engine life, provided the cracks are

wit
, is n
small and not more than 0.5 mm wide.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Valve gear 127

1 - Valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Mark installation posi‐
tion for re-installation.
❑ Checking ⇒ page 150 .
❑ Valve dimensions
⇒ page 149
❑ Checking valve guides
⇒ page 149 .
2 - Cylinder head lkswage es n
o ot g
byV ua
d
3 - Valve stem seal orise ran
tee
th or
❑ Renew with scylinder
au ac
head installed
s
ce
e
nl
⇒ page 142
pt
du
an
itte
❑ Renewing with cylinder
y li
erm
ab
head removed
ility
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⇒ page 145 .
wit
, is n
h re
4 - Valve spring
hole
spec
5 - Valve spring plate
es, in part or in w
t to the co
6 - Valve cotters
7 - Cap
rrectness of i
❑ Renew.
l purpos
❑ Removing: With retain‐

ing frame installed,
pierce one side of cap
nform
ercia
with an awl and pry out.

m
at
❑ Installing: Drive in with‐

om
ion
out sealant using an ap‐

c
in t
or
propriate thrust piece.

his
ate
do
riv
❑ Insertion depth 1 … 2
p
cum
or
mm.
f
en
ng
t.
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8 - Oil seal Cop py
t. rig
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pyri by
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by
cted
9 - Exhaust camshaft
agen
Prote AG.

❑ Measuring axial clearance ⇒ page 129 .
❑ Measuring radial clearance ⇒ page 130
10 - Bolt
11 - Retaining frame
❑ With integrated camshaft bearings.
12 - Inlet camshaft
❑ Measuring axial clearance ⇒ page 129 .
❑ Measuring radial clearance ⇒ page 130
13 - Roller rocker finger
❑ Mark installation position for re-installation.
❑ Check roller bearing for ease of movement.
❑ Lubricate contact surfaces before installing.

14 - Securing clip
❑ For hydraulic compensation element.
15 - Hydraulic compensation element
❑ Mark installation position for re-installation.
❑ Lubricate contact surfaces before installing.
Retaining frame - specified torques and installation sequence

– Tighten bolts in 2 stages in the sequence shown: AG. Volkswagen AG d
agen oes
olksw not
Stage Bolts Specified torque ed byV gu
ara
ris nte
1 -1- to -24- Screw in to contactut by hand.
ho eo
ra
• The retainings frame must make
s a c
contact with the cylinder head over
ce
le
un
pt
the entire contact surface.
an
d
itte
y li
rm
ab
2 -1- to -24- 10 Nm
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
3.2 Measuring axial play of camshaft
nform
mercia
a
com
tion in
♦ Universal dial gauge bracket - VW 387-
r
te o
thi
s
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Cop py
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Prote AG.
Procedure
– Remove retaining frame ⇒ page 134 .
3. Valve gear 129

– Fasten dial gauge - VAS 6079- to cylinder head with universal

dial gauge bracket - VW 387- as shown in the illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048…0.118 mm.
• Wear limit: 0.17 mm.
3.3 Measuring radial play of camshaft

♦ Plastigage
Procedure
– Remove roller rocker finger.
– Remove bearing cap and clean crankshaft journal.
– Place a length of Plastigage corresponding to nthe
wage
AGwidth
. Volkswof
agthe
en AG
does
bearing on the journal to be measured
yV
oor
lksinto the bearings. not
g b ua
ed ran
• The Plastigage must lie in the middle
ho
ris of the bearing. tee
t or
au ac
– Fit retaining frame and tighten
ss to 10 Nm ⇒ page 129 without
twisting crankshafts. ce
e
nl
pt
du
an
itte
– Remove retaining frame. y li

erm
ab
ility
– Compare width of Plastigage with the measurement scale.
ot p
wit
, is n
• Radial clearance: 0.035 … 0.085 mm.

h re
hole
spec
3.4 Removing and installing camshaft oil

es, in part or in w
t to the co
seal
rrectness of i
Note
l purpos
A new seal -B- will be gradually introduced. This new seal does
not provide a closed surface between the camshaft and cylinder
nform
ercia
head but has a fillet. A different procedure has to be followed here

⇒ page 132 .
m
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
3.4.1 Vehicles with »old« seal


equipment required
♦ Fitting tool - V.A.G 10-203-
♦ Oil seal extractor - 3240-
1331/-
1332/-
♦ Bolt M12 x 1.5 x 75
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
Seal -A-
an
d
itte
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erm
ab
Removing
ility
ot p
– Remove toothed belt from camshaft and high-pressure pump wit

is n
h re
⇒ page 110 .
ole,
spec
– Remove camshaft sprocket and hub ⇒ page 134 .

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Valve gear 131

– Insert thrust piece -3240/1- into camshaft.

– Unscrew inner part of oil seal extractor 3240 2 turns (approx.
3 mm) from outer part and lock using knurled screw.
AG. Volkswagen AG d
agen oes
o lksw not
V gu
by
– Lubricate threaded head of oil seal extractor,risplace
e d it in posi‐ ara
nte
tion and, exerting firm pressure, screw it into
ut
ho oil seal as far as eo
ra
possible. ss a c
ce
le
– Loosen knurled screw and turn inner part against camshaft

un
pt
an
d
until oil seal is pulled out.

itte
y li
rm
ab
Installing
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Fit guide sleeve of fitting tool - 10 - 203- onto camshaft as

shown in illustration.
nform
ercia
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press seal in as far as stop using thrust piece from fitting tool
10-203 and bolt M12×1.5x75.
– Install camshaft sprocket and hub ⇒ page 134 .
– Install toothed belt and adjust the valve timing ⇒ page 110 .
3.4.2 Vehicles with »new« seal


equipment required
♦ Fitting tool - V.A.G 10-203-
♦ Oil seal extractor - T10443-
1331/-
1332/-
♦ Bolt M12 x 1.5 x 75
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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Seal -B-
erm
ab
ility
ot p
Removing
wit
is n
h re
– Removed toothed belt from camshaft and high-pressure pump

ole,
spec
⇒ page 110 .
t to the co
– Remove camshaft sprocket and hub ⇒ page 134 .
Caution
rrectne
If turned back too far, the internal pressure plate moves off the
ss
pressure screw. In this case the pressure plate must be fixed

o
cial p
f i
on to the pressure bolt again.

nform
mer
atio
om
– »Use your own discretion« and turn pressure bolt of the oil seal
c
i
or
extractor back until you feel slight resistance.

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
3. Valve gear 133

Note
The clamping sleeves of oil seal extractor are provided with set
screws. However, only one of these grub screws -arrow- effects
clamping. The other is screwed tight.
– Position oil seal extractor straight, as shown, and clamp by

turning set screw -A-.
– Screw in pressure bolt -B- until seal is pulled out.
Installing
Note
– Fit guide sleeve of fitting tool - 10 - 203- onto camshaft as

shown in illustration. The inscription on the seal faces out‐
wards.
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
– Press the seal in as far as stop using thrust piece from fitting
an
itte
y li
tool 10-203 and bolt M12×1.5x75.

erm
ab
ility
ot p
– Install camshaft sprocket and hub ⇒ page 134 .

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
3.5 Removing and installing camshaft

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted
134
agen
Prote AG.
Rep. gr.15 - Cylinder head, valve gear

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Puller - T10052-
♦ Camshaft fitting tool -
T40094-
♦ Camshaft clamping tool -
T40095-
♦ Camshaft fitting tool -
T40096-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
♦ Torque wrench - V.A.G 1331/- ss a c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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135
c by lksw
cted agen
Prote AG. 3. Valve gear
♦ Torque wrench - V.A.G 1332/-
♦ Silicone adhesive sealant - D 176501 A1-

Removing
– Remove fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and
installing fuel filter .
Golf Cabriolet:
V277- , and lay it to one side (fuel lines remain connected)
. Volksw⇒
agen AG
Fuel supply – diesel engines; Rep. gr. 20 o;lkFuel gen AG
swa pump; Re‐ does
not
moving and installing fuel pump . d by V gu
ar
e an
ris tee
Continuation for all vehicles: utho or
a ac
ss
– Removed toothed belt from camshaft and high-pressure pump
ce
e
nl
⇒ page 110 .
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove securing bolts -1- of camshaft pulley. wit

, is n
h re
– Remove camshaft sprocket from hub.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
– Counterhold hub with counterhold tool - T10051- and release

or c
hub securing bolt -1-.

thi
te
sd
iva
o
r
– Unscrew hub securing bolt approx. 2 turns.

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Position puller - T10052- and align with hub holes.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with 30 mm spanner whilst doing this.
– Remove hub from taper of camshaft.

– Remove vacuum pump ⇒ page 104 .
– Unscrew retaining frame securing bolts in sequence -24- to

-1-.
– Remove retaining frame.
– Carefully remove camshafts.
Installing
Note
Seal parting surface between retaining frame and cylinder head

using silicone adhesive sealant - D 176 501 A1- .
Caution
The camshafts may only be installed with the camshaft fitting

tool - T40094- as described below. The axial bearings in the
retaining frame will otherwise be damaged beyond repair and swagen AG. Volkswagen AG does
the cylinder head will have to be renewed. yV
olk not
gu b ara
ed nte
oris e
th or
au ac
– Remove sealant residues on cylinder head andss retaining
frame, e.g. using a rotating plastic brush.
ce
le
un
pt
an
d
itte
y li
erm
ab
Caution
ility
ot p
wit
is n
Make sure that no sealant residue gets into the cylinder head h re
ole,
or the bearings.
spec
t to the co

• Sealing surfaces must be free of oil and grease.
rrectne
– Oil running surfaces of camshafts.

ss
Set up camshaft fitting tool - T40094- for camshafts as follows:

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Valve gear 137

– Remove supports -T40094/3-, -T40094/4- and -T40094/5-

from base plate. Undo threaded connection from below.
Note
If the supports of the camshaft fitting tool - T40094- are not yet
marked, mark the removed supports, e.g. with number stamps,
so they can be fitted in the original positions later.
– Install supports -T40094/9- and -T40094/10- at vacant outer

positions.
– Install support -T40094/2- at position “A” and support
-T40094/1- at position “F”.
– Insert inlet camshaft groove as shown. Ensure that indentation
-arrow- for cylinder head bolt faces »outwards«.
– Position 0.50 mm feeler gauge and push the support

-T40094/8- into inlet camshaft groove.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Insert exhaust camshaft and lock via groove -arrow- with

es, in part or in w
-cover T40094/11-.
t to the co
– Position clamping tool - T40096/1- on exhaust camshaft

sprockets.
rrectness of i
l purpos
Caution
Ensure that the clamping jaw marked with an arrow is seated

nform
ercia
on the wider gear.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Tighten clamping tool - T40096/1- using knurled wheel so that

faces of gear teeth are in alignment. Use a 13 AF open-ended
spanner.
– Slide exhaust camshaft towards inlet camshaft until teeth en‐
gage.
– Place retaining frame on camshafts.
• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool - T40095- as shown, thereby fix‐

ing camshafts in position in retaining frame.
– Remove cover - T40094/11- .
– Pull support - T40094/8- out of inlet camshaft groove.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
2 mm).
h re
hole
spec
– Apply beads of sealant (approx. 2…3 mm wide) -arrows- onto
es, in part or in w
clean sealing surfaces of cylinder head as illustrated.
t to the co
Caution
rrectness of i
Risk of soiling camshaft bearings due to surplus sealant and
l purpos
risk of sealing oil supply bores.

♦ Do not apply sealant beads thicker than specified.
nform
ercia
♦ In area of oil supply holes-arrow- for retaining frame, make

m
a
sure that these are not sealed due to surplus sealant.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Valve gear 139

AG. Volkswagen
n AG do
wage es n
olks ot g
Sealant bead for retaining frame ed
by
V ua
ran
ris tee
– Remove camshafts from camshaft fittingau
th tool - T40095- to‐
o
or
ac
gether with retaining frame and camshaft
ss fitting tool - T40094- .
ce
le
un
– Carefully insert camshafts and retaining frame into cylinder
pt
an
d
itte
head.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– First tighten securing bolts of retaining frame hand-tight in se‐
i
or
n thi
quence -1- to -24-.
te
sd
iva
o
pr
c
• The retaining frame should make contact with the cylinder
um
r
fo
head over the complete surface.
en
ng
t.
yi Co
op
– Tighten bolts of the retaining frame in the sequence -1- to
C py
t. rig
gh
-24- to 10 Nm.
ht
pyri by
Vo
co lksw
by
cted
– Remove camshaft fitting tool - T40095- and clamping tool -
agen
Prote AG.
T40096/1- .
– Renew camshaft seal ⇒ page 130 .
– Using a suitable drift, knock new sealing cap (core plug)
⇒ Item 7 (page 128) in cylinder head until flush.
Perform further installation in reverse order, paying attention to
the following:
Caution
Avoid damage to valves and piston crowns after working on

valve gear.
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
– Fit hub on camshaft.

– Tighten securing bolt -1- of the hub. Use counterhold tool -

T10051- to do this.
– Push camshaft sprocket onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
wage e
– Insert securing bolts Vo-1-
lks by hand without play toscamshaft
not
gu
by
sprocket. ised ara
nt
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tho or
– Lock hub swith
au diesel injection pump locking pin - 3359- . ac
s
ce
le
un
pt
an
d
itte
– Install vacuum pump ⇒ page 104 .

y li
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ab
pe
ility

ot
wit
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– Install fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and

h re
hole
installing fuel filter .

spec
es, in part or in w
t to the co
Specified torques
rrectness of i
Retaining frame 10 Nm
l purpos
Securing bolt of the hub 100 Nm

Toothed-belt pulley on the hub 20 Nm +45°
nform
mercia
a
com
tion in
3.6 Checking hydraulic compensation ele‐

r
te o
thi
s
iva
ments
do
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Note C py
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♦ The hydraulic compensation elements cannot be repaired.
by c lksw
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Prote AG.
♦ Irregular valve noise during starting is normal.

♦ Feeler gauges
Procedure
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to about 2,500 rpm for 2 minutes; per‐
form road test if necessary.
3. Valve gear 141

Note
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If the irregular valve noises stop y Vbut recur repeatedly during short
olk not
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journeys, the oil retention valveed b must be renewed. The oil reten‐ uara
ris nte
tion valve is located in the
ut oil filter bracket
ho eo
ra
⇒ Item 10 (page 168)ss. a c
ce
le
un
pt
– If the hydraulic compensation elements are still noisy, find out
an
d
itte
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which is the defective compensation element as follows:
rm
ab
pe
ility
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– Turn crankshaft by the bolt for the toothed belt wheel until cam
hole
spec
of supporting element to be tested is facing upwards.
es, in part or in w
t to the co
– Press roller rocker finger downwards -arrow- to check clear‐
ance between cam and roller rocker finger.
– If a 0.20 mm feeler gauge can be inserted between cam and
rrectness of i
roller rocker finger, replace hydraulic compensation element.
l purpos
Concluding measures
nform
mercia
a
com
tion in
r
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thi
s
iva
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cum
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3.7 Removing and installing valve stem

t.
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Cop py
seals
t. rig
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⇒ “3.7.1 Removing and installing valve stem seals with cylinder cted agen
Prote AG.
head installed”, page 142
⇒ “3.7.2 Removing and installing valve stem seals with cylinder
head removed”, page 145
3.7.1 Removing and installing valve stem

seals with cylinder head installed
♦ Valve stem seal puller - 3364-

♦ Valve stem seal fitting tool - 3365-
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♦ Removal andoriinstallation
se device for valve cotters - VAS n5161-
tee
with guideauplate
th -VAS 5161/23- and sleeve -VAS 5161/23-1- or
ac
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♦ 2x M6x30 bolts rrectness
Procedure
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– Remove all glow plugs ⇒ page 355 .

form
mer
atio
– Remove camshafts ⇒ page 134 .

om
n
c
– Mark allocation of roller rocker fingers and hydraulic compen‐

or
n thi
e
sation elements for reinstallation.

t
sd
iva
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pr
– Remove roller rocker fingers together with hydraulic compen‐

um
r
fo
en
ng
sation elements and place down on a clean surface.

t.
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op py
– Set piston of respective cylinder to “bottom dead centre”.
t. C rig
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pyri by
Vo
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– Place guide plate -VAS 5161/23- onto cylinder head. by c lksw
cted agen
Prote AG.
– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
3. Valve gear 143

– Screw sealing pins -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into relevant glow
plug thread.
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter to compressed air supply using a commer‐
cially available union and apply
agen
pressure
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• Minimum pressure:
d b6 bar
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– Attach pressure
ut fork -VAS 5161/2- to toothed piece and press
ho
or
assembly cartridge
ss
a
down. ac
ce
le
un
– At the same time, turn knurled screw of assembly cartridge

pt
an
d
clockwise until tips engage in valve cotters.

itte
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rm
ab
pe
– Move knurled screw back and forth to press apart valve cotters
ility
ot
and capture them in assembly cartridge.

wit
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– Release pressure fork.

hole
spec
es, in part or in w
– Remove assembly cartridge with knurled spacer ring.

t to the co
– Remove valve spring and valve spring plate.

rrectness of i
– Pull off valve stem seal using valve stem seal puller - 3364- .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

Caution
Risk of damage when installing valve stem seals. lkswage es n
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byV ua
♦ Place plastic sleeve -A-, enclosed with new valve ed
ir sstem
ran
o tee
seals -B-, onto valve stem. auth or
ac
ss
ce
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un
pt
an
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– Lightly oil sealing lip of valve stem seal.
itte
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erm
ab
– Push valve stem oil seal onto plastic sleeve.
ility
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wit
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– Carefully press valve stem oil seal onto valve guide using
h re
valve stem seal fitting tool - 3365- .
ole,
spec
– Remove plastic sleeve.
t to the co
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device -
rrectne
VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
ss o
cial p
f
– Insert valve spring and valve spring plate.
inform
mer
– Press assembly cartridge onto valve cotter insertion device
atio
m
from above and pick up valve cotters.

o
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
– Insert assembly cartridge into guide plate -VAS 5161/23-
t. rig
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again. p by
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cted agen
– Press pressure fork downwards and pull knurled screw up‐ Prote AG.
wards, turning it clockwise and anticlockwise. This inserts the

valve cotters.
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
– Repeat procedure on each valve.
Reassembly
Installation is carried out in the reverse order. In the process, note
the following:
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensation
elements.
– Install camshafts ⇒ page 134 .
– Install glow plugs ⇒ page 355 .
3.7.2 Removing and installing valve stem seals with cylinder head removed
3. Valve gear 145


equipment required
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation agen
AG. Volkswagen AG d
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device for valve cotters - Volksw not
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VAS 5161- with guide plate d by ara
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-VAS 5161/23- and sleeve - hor eo
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VAS 5161/23-1- ss a ra
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♦ Engine and gearbox sup‐
nl
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an
port - VAS 6095-
itte
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♦ Cylinder head tensioning
ility
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device - VAS 6419-
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♦ 2x M6x30 bolts
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Procedure
– Remove camshafts ⇒ page 134 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Tension cylinder head on cylinder head tensioning device as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve disc.

AG. Volkswagen AG d
– Place guide plate -VAS 5161/23- onto cylinder head. agen oes
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by ara
– Tighten guide plate on intake manifold side by hand using
rised
nte
knurled screw -VAS 5161/12- and 2 M6x30 bolts -itemaut
ho
1- until eo
ra
it makes contact. ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Insert drift -VAS 5161/3- into guide plate and use a plastic
rrectness of i
hammer to knock loose the firmly seated valve cotters. l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh
– Screw toothed piece -VAS 5161/6- with hooking fork -
ht
pyri by
Vo
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VAS 5161/5- into guide plate. by c lksw
cted agen
Prote AG.
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge with knurled spacer ring.
– Remove valve spring and valve spring plate.
– Pull off valve stem seal using valve stem seal puller - 3364- .
3. Valve gear 147

Caution
Risk of damage when installing valve stem seals.

♦ Place plastic sleeve -A-, enclosed with new valve stem
seals -B-, onto valve stem.
– Lightly oil sealing lip of valve stem seal.

– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If the valve cotters have been removed from the assembly car‐
tridge, they must first be inserted into the valve insertion device -
VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto valve cotter insertion device
from above and pick up valve cotters.
AG. Volkswagen AG d
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lksw not
– Insert assembly cartridge dintoby guide plate -VAS 5161/23-
Vo gu
ara
again. orise nte
eo
h
ut ra
– Press pressure fork
ss adownwards and pull knurled screw up‐ c
wards, turning it clockwise and anticlockwise. This inserts the
ce
le
un
pt
valve cotters.
an
d
itte
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erm
– Reduce pressure on pressure fork whilst pulling on knurled

ab
ility
screw.
ot p
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– Repeat procedure on each valve.

h re
ole,
spec
Reassembly
t to the co
Installation is carried out in the reverse order. In the process, note

the following:
rrectne
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensation
elements.
ss o
cial p
– Install camshafts ⇒ page 134 .

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

4 Inlet and exhaust valves

⇒ “4.1 Valve dimensions”, page 149
⇒ “4.2 Reworking valve seats”, page 149
⇒ “4.3 Checking valve guides”, page 149
⇒ “4.4 Checking valves”, page 150
4.1 Valve dimensions
Note
Inlet and exhaust valves must not be reworked. Only lapping-in

is permitted.
Dimension Inlet valve Exhaust valve

wage es n
∅a mm 28.10 26.00
yV
olks ot g
d b ua
ran
∅b mm 5.975 o
ir se 5.965 tee
th or
c mm 99.30 ss
au
99.10 ac
α ∠° 45 45
ce
e
nl
pt
du
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4.2 Reworking valve seats
ility
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Note
spec
es, in part or in w
t to the co
Valve seats must not be reworked due to the very narrow toler‐
ances.
rrectness of i
4.3 Checking valve guides
l purpos
nform
ercia
♦ Universal dial gauge bracket - VW 387-

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
4. Inlet and exhaust valves 149

AG. Volkswagen AG d
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Procedure ss a ra
c
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pt
du
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Note
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ility
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♦ If the valve is to be renewed as part of a repair, use a new
wit
, is n
valve for the measurement.
h re
hole
spec
♦ Due to differing stem diameters, only use an intake valve in
es, in part or in w
intake guide and an exhaust valve in exhaust guide.
t to the co
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
rrectness of i
– Insert valve into valve guide.
l purpos
• The end of the valve stem must be flush with the guide.
nform
ercia
– Determine rock.
m
at
om
• Wear limit: 1.0 mm

ion
c
in t
or
– If the wear limit is exceeded, repeat the measurement with

his
ate
new valves.
do
priv
cum
or
– Renew cylinder head if wear limit is still exceeded.

f
en
ng
t.
yi Co
Cop py
t. rig
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Note pyri by
Vo
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by c lksw
cted agen
Prote AG.
Valve guides cannot be exchanged.
4.4 Checking valves

– Check for scoring on valve stems and valve seat surfaces.
– Exchange valve if significant scoring can be seen.

agen
AG. Volkswagen AG d
oes CC 2012 ➤ , Golf Cabriolet 2012 ➤
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y V 4-cylinder diesel engine (2.0otl gengine,
ol
u common rail, generation II) - Edition 09.2013
db ara
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17 – Lubrication
ss c
ce
e
nl
pt
du
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itte
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1 Sump, oil pump
erm
ab
ility
ot p
wit
⇒ “1.1 Assembly overview - sump / oil pump”, page 151
, is n
h re
hole
⇒ “1.2 Removing and installing oil sump”, page 156
spec
es, in part or in w
⇒ “1.3 Removing and installing oil level and oil temperature send‐
t to the co
er”, page 160
⇒ “1.4 Removing and installing oil pump”, page 161
rrectness of i
⇒ “1.5 Engine oil”, page 162
l purpos
1.1 Assembly overview - sump / oil pump
nf
ercia
o
⇒ “1.1.1 Assembly overview - sump / oil pump, engine code
rm
m
CFHC”, page 151
atio
om
n in
c
⇒ “1.1.2 Assembly overview - sump/oil pump, engine codes

or
thi
CFFA, CFFB, CFGB, CFGC, CLLA”, page 154
te
sd
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rp
cu
1.1.1 Assembly overview - sump / oil pump,
o
m
f
en
ng
engine code CFHC

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
♦ Metal shavings or a large quantity of small metal particles

found during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To avoid any sub‐
sequent damage, the following work must be carried out fol‐
lowing the repair: Carefully clean oil channels and renew oil
spray jets, engine oil cooler and oil filter.
♦ Oil capacities, oil specifications, viscosity grades ⇒ Mainte‐
nance tables .
1. Sump, oil pump 151

1 - Oil level and oil temperature

sender - G266-
⇒ page 160 AG. Volkswagen AG d
agen oes
lksw not
2 - O-ring d by Vo gu
ara
❑ Renew. rise nte
tho eo
au ra
3 - Oil drain plug ss c
ce
e
nl
❑ 30 Nm
pt
du
an
itte
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4 - Seal
erm
ab
ility
ot p
❑ Renew.
wit
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h re
5 - Bolt
hole
spec
❑ Specified torque and
es, in part or in w
tightening sequence
t to the co
⇒ page 160 .
6 - Oil sump
rrectness of i
❑ Clean sealing surface
before fitting.
l purpos
❑ Install with sealant ac‐

cording to ⇒ Electronic
nform
ercia
Parts Catalogue (ET‐

m
KA) .
at
om
io
n
c
in t
or
⇒ page 156 his

ate
do
riv
7 - Bolt
p
cum
for
❑ 16 Nm
en
ng
t.
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op py
8 - Oil pump t. C rig
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❑ With 12 bar pressure re‐ cop Vo
by lksw
lief valve cted agen
Prote AG.
that both dowel sleeves
for centring oil pump on
cylinder block are fitted.
Note
♦ If toothed belt or oil pump have

to be removed.
♦ Check oil pump for free move‐
ment.
♦ It should be possible to turn belt
pulley easily with 1 finger.
♦ Renew if tight/sticking.
9 - Toothed belt
❑ Check for damage and wear
❑ Replace if necessary
Note
♦ Belts which have been in use

longer can sag.
♦ This is not a fault and does not
necessarily mean belt needs re‐
placing.
152 Rep. gr.17 - Lubrication

. Volkswagen AG
10 - Dowel sleeveskswagen AG does
not
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11 - Cylinder by
dblock ara
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12 - O-ring
aut ra
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ss
❑ Renew.
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13 - Bolt
itte
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ab
❑ 9 Nm
pe
ility
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wit
14 - Clip
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hole
15 - Dipstick guide tube
spec
es, in part or in w
16 - Bolt
t to the co
❑ 9 Nm
17 - Oil suction pipe
rrectness of i
18 - Baffle plate
l purpos
19 - Bolt
nform
ercia
❑ 16 Nm
m
a
20 - Bolt
com
tion in
❑ Self-locking.
r
te o
thi
❑ Renew. s
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❑ 9 Nm
um
fo
en
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t.
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Cop py
t. rig
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Oil spray jet and pressure relief valve
ht
pyri by
Vo
co lksw
by
cted
1- Bolt with pressure relief valve, 27 Nm
agen
Prote AG.
2- Oil spray jet (for cooling of pistons)
Note
When renewing the oil spray jet, ensure correct allocation to pis‐
ton ⇒ Electronic Parts Catalogue (ETKA) .
Oil sump - specified torques and installation sequence
Note
Renew bolts for oil sump.
– Tighten bolts in 3 stages:

1 -1- to -20- In diagonal sequence, 5 Nm
2 -arrows- 40 Nm
3 -1- to -20- In diagonal sequence and in stages;
final torque 15 Nm

en AG. V
olcommon
kswagen AGrail, generation II) - Edition 09.2013
ag does
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Vol gu
1.1.2 Assembly overview - sump/oil pump, engine codes CFFA, CFFB, CFGB, by ara
ed nte
oris
CFGC, sCLLA th eo
au ra
c
s
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
♦ Metal shavings or a large quantity of small metal particles found during engine repair could indicate that the
wit
, is n
crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work
h re
must be carried out following the repair: Carefully clean oil channels and renew oil spray jets, engine oil
hole
spec
cooler and oil filter.
es, in part or in w
t to the co
♦ Oil capacities, oil specifications, viscosity grades ⇒ Maintenance tables .
♦ Oil spray jet and pressure relief valve ⇒ page 153
rrectness of i
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1 - Seal
❑ Permanently attached
nf
ercia
o
to drain plug.
rm
m
atio
m
2 - Oil drain plug, 30 Nm

o
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or c
3 - Oil sump
thi
te
sd
iva
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rp
cu
⇒ page 156
o
m
f
en
ng
t.
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4 - 9 Nm t. Cop py
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5 - Suction line yri
p by
o Vo
by c lksw
❑ Clean strainer if soiled. cted agen
Prote AG.
6 - O-ring
❑ Renew.
7 - Oil pump
⇒ page 161
that the two dowel
sleeves for centring oil
pump on balancer shaft
module are fitted.
8 - Drive shaft
❑ For oil pump.
9 - Circlip
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
10 - Spur gear
❑ For balancer shaft.
❑ Renew.
12 - Thrust washer
❑ For intermediate gear wheel.
❑ Renew.
❑ Installation position ⇒ page 156 .
❑ To install intermediate gear wheel, secure to balancer shaft module with grease.

13 - Intermediate gear wheel

❑ Renew.
❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
wear.
❑ Installation position: Part number must be visible.
❑ Make sure thrust washer is seated correctly ⇒ page 156 .
14 - 90 Nm + 90°
❑ With washer.
❑ Renew.
15 - Hub
❑ Renew.
16 - Crankshaft sprocket
17 - Balancer shaft module
❑ Removing ⇒ page 178
❑ Reinstalling previously run balancer shaft module ⇒ page 179 .
❑ Installing new balancer shaft module ⇒ page 182 .
❑ Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block
are fitted.
18 - M7 = 13 Nm + 90° further; M8 = 20 Nm + 90° further
❑ Renew.
❑ Note tightening sequence: installing new balancer shaft module ⇒ page 182 , reinstalling previously run
balancer shaft module ⇒ page 179 .
19 - Dowel sleeves
20 - 9 Nm
AG. Volkswagen AG d
21 - Oil extraction pipe agen oes
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d
22 - 9 Nm orise nte
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23 - Seal ss a c
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❑ Renew.
nl
pt
du
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24 - Oil level and oil temperature sender - G266-

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Oil sump - specified torques and installation sequence
Note
Renew oil sump bolts.

1 -1 … 20- In diagonal sequence, 5 Nm
2 -arrows- 40 Nm
3 -1 … 20- In diagonal sequence and in stages;
final torque 15 Nm
Thrust washer installation position
Caution
Risk of thrust washer slipping behind intermediate gear wheel.

♦ When installing intermediate gear wheel, make sure that
thrust washer -A- does not slip out of balancer shaft mod‐
ule indentations -arrows- and subsequently become n Ajam‐
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♦ Metal shavings or a large quantity of small metal particles spec

found during engine repair could indicate that the crankshaft

t to the co
bearings or conrod bearings are damaged. To avoid any sub‐

sequent damage, the following work must be carried out fol‐
lowing the repair: Carefully clean oil channels and renew oil
rrectne
spray jets, engine oil cooler and oil filter.

♦ Oil capacities, oil specifications, viscosity grades ⇒ Mainte‐
ss
nance tables .
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mer

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♦ Jointed wrench 10 mm - 3185-

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– Remove coolant circulation pump 2 - V178- ⇒ page 204 .
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– In vehicles with an auxiliary heater, remove the bracket for the
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– Unscrew bolts -arrows- of sump to gearbox connection.

– Slacken bolts -1- to -20- in diagonal sequence and remove.
– Release oil sump carefully from adhesive.
Installing
Caution
Danger of soiling lubrication system and bearings.

♦ Cover open parts of engine.
WARNING
Risk of eye injury. agen

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– Remove sealant residues from sump and cylinder block using

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♦ Do not apply sealant bead thicker than specified.
– Apply bead of sealant onto clean sealing surface of sump as

illustrated.

• Thickness of sealant bead: 2 - 3 mm.
Note
♦ Take particular care when applying the sealant bead near the
rear sealing flange -arrows-.
♦ The sump must be installed within 5 minutes after sealant is
applied.
– Position oil sump and tighten bolts.

• The oil sump must be flush with the gearbox flange at the in‐
termediate plate.
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Oil sump - specified torques and installation
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– Tighten bolts in 3 stages: s
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1 -1- to -20- In diagonal sequence, 5 Nm
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3 -1- to -20- In diagonal sequence and in stages;
hole
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final torque 15 Nm
es, in part or in w
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Note
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♦ When installing sump with engine removed from vehicle, en‐
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sure that sump is flush with cylinder block at flywheel end.

♦ Allow sealant to dry for approx. 30 minutes after installing
nf
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sump. Only then fill with engine oil.
orm
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– Replenish engine oil and check oil level ⇒ Maintenance ;
n in
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Booklet .
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– Install charge-air cooler ⇒ page 240 .
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– Install coolant circulation pump 2 - V178- ⇒ page 204 .

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– Noise insulation for oil sump.
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– Install noise insulation ⇒ General body repairs, exterior; Rep. by c lksw
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tion .
1.3 Removing and installing oil level and oil

temperature sender
Removing
– Drain engine oil ⇒ Maintenance ; Booklet 24.1 .
– Disconnect electrical connector -arrow- on oil level and oil
temperature sender - G266- .


– Unscrew bolts -1- and remove oil level and oil temperature
sender - G266- -item 4-.
Installing
• Specified torque ⇒ Item 20 (page 153) .
Installation is carried out in the reverse order; note the following:
Note
G. Volkswagen AG d
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lksbolts
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– Replenish engine thoil
or and check oil level ⇒ page 163 . eo
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1.4 Removing and installing oil pump
spec
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Removing
rrectne
– When oil pump is to be renewed, unscrew bolts -4- and remove
oil intake pipe -3-.
ss
– Unscrew bolts -arrows- and remove baffle -2-.
o
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– Detach oil pump -1- from toothed belt and remove pump.
mer
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Installing
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Renew O-ring.
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– Insert new dowel sleeves when oil pump has no dowel sleeves
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h re
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Renew sluggish oil pump.
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– Check toothed belt for oil pump.
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– Fit oil pump with toothed belt pulley into toothed belt and tight‐
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– Replenish engine oil and check oil level ⇒ page 163 .
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1.5 Engine oil
Note
The oil level must not be above the max. mark - danger of damage
to catalytic converter! Markings ⇒ page 163 .
Drain engine oil ⇒ Maintenance ; Booklet ; Engine oil: Drain or

extract; renew oil filter and replenish engine oil .
Engine oil specifications ⇒ Maintenance ; Booklet ; Service tables
⇒ “1.5.1 Oil capacities”, page 162
⇒ “1.5.2 Checking engine oil level”, page 163
1.5.1 Oil capacities

With oil filter change: 4.3 l
Without oil filter change: 4.0 l

1.5.2 Checking engine oil level
Note
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
ing. This is a perfectly normal and self-regulating characteristic.
It is not necessary to adjust the engine oil level.
1 - Min. mark
2 - Max. mark
a - Oil level in min. mark area: replenish engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Oil level in max. mark area: Do not replenish engine oil!
d - The oil level may be in this area as a result of particular driving
conditions.
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2 Engine oil cooler
tee
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⇒ “2.1 Assembly overview - engine oil cooler”, page 164
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⇒ “2.2 Removing and installing engine oil cooler”, page 165
itte
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2.1 Assembly overview - engine oil cooler
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Note
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Metal shavings or a large quantity of small metal particles found
during engine repair could indicate that the crankshaft bearings
or conrod bearings are damaged. To avoid any subsequent dam‐
rrectness of i
age, the following work must be carried out following the repair:
l purpos
Carefully clean oil channels and renew oil spray jets, engine oil
cooler and oil filter.
nform
mercia
a
1 - Cap
com
tion in
❑ 25 Nm
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2 - O-ring
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❑ Renew.
5 - Oil filter element
❑ See note ⇒ page 164 .
⇒ Maintenance ; Book‐
let
6 - Engine oil cooler
❑ Coolant hose schematic
diagram ⇒ page 186 .
⇒ page 165
❑ Change coolant after re‐
newing.
7 - 11 Nm
8 - Gaskets
❑ Renew.
9 - Bolt
❑ Renew.
10 - Oil filter housing
❑ With integrated oil re‐
tention valve.
❑ Removing and installing ⇒ “3.2 Removing and installing oil filter housing”, page 169
11 - Gaskets
❑ Renew.

2.2 Removing and installing engine oil cool‐

er
♦ Used oil collection and extraction unit - V.A.G 1782-
AG. Volkswagen AG d
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Removing
– Remove radiator cowl ⇒ page 223 .
– Place drip tray for workshop crane - VAS 6208- under point of
separation.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
2. Engine oil cooler 165

– In addition to draining coolant from engine, detach coolant

hose from oil filter holder -arrow-.
– Remove bolts -arrows- from engine oil cooler -1-.

– Remove engine oil cooler -1- from oil filter housing.
Installing
Install in the reverse order of removal and observing the following
while doing so:
AG. Volkswagen AG d
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Note d byV gu
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♦ Renew gaskets, seals and ut
O-rings.
a ra
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♦ Hose connections and air intake pipes/hoses must be free of
le
un
pt
oil and grease when installing.
an
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ab
♦ Secure all hose connections with the hose clips corresponding
ility
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to original equipment ⇒ Electronic Parts Catalogue (ETKA) .
wit
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spec
– Insert new seal -1- on the oil-filter housing.
t to the co
– Carefully slide the engine oil cooler onto centring pins.
rrectness o
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mer
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– Press on oil cooler until it is flush -1- with the end of centring
um
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pins.
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– Start new bolts and screw in until heads make contact.
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– Tighten bolts -arrows- alternately in diagonal sequence in 3

steps.
♦ Step 1: tighten by hand
♦ Step 2: tighten to 5 Nm n AG. Volkswagen AG do
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♦ Step 3: tighten to 11 Nm byV
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– Install oil filter element, replenish engineuthoil and check oil level
o tee
or
⇒ page 163 . ss
a ac
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– Replenish coolant in cooling system, change coolant if engine
un
pt
an
d
oil cooler has been renewed ⇒ page 189 .
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2. Engine oil cooler 167

3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter ”, apage 168
gen AG
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⇒ “3.2 Removing and installing
ed
boil
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ac
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⇒ “3.4 Checking oil pressure and oil pressure switch”,
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page 172
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3.1 Assembly overview - oil filter
erm
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1 - Cap
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spec
❑ 25 Nm
es, in part or in w
t to the co
2 - O-ring
❑ Renew.
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3 - O-ring
l purpos
❑ Renew.
4 - O-ring
nform
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❑ Renew.
m
at
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5 - Oil filter element
on
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⇒ Maintenance ; Book‐
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let 808
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rig ht
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❑ See note ⇒ page 164 . co Vo
by lksw
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⇒ “3.2 Removing and in‐
stalling oil filter hous‐
ing”, page 169
newing.
7 - 11 Nm
8 - Gaskets
❑ Renew.
9 - Bolt
❑ Renew.
❑ Specified torque and
tightening sequence
⇒ page 169 .
10 - Oil filter bracket
❑ With integrated oil retention valve.
❑ Removing and installing ⇒ “3.2 Removing and installing oil filter housing”, page 169
11 - Gaskets
❑ Renew.

Oil filter bracket - specified torques and sequence
Note
Renew bolts for oil filter bracket.
– First tighten upper left and lower right bolts.

Stage Bolts Specified torque/turning further angle
1 -arrows- In diagonal sequence, 14 Nm
2 -arrows- Turn 90° further using diagonal se‐
quence
3.2 Removing and installing oil filter housing

♦ Removal lever - 80 - 200-
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♦ Used oil collection and extraction unit - V.A.G 1782-
hole
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3. Oil filter, oil pressure switch 169

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4-cylinder diesel engine (2.0 l engine, common
ss rail, generation II) - Edition 09.2013 c
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Removing
m
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– Remove radiator cowl ⇒ page 223 .
s
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um
fo
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t.
– Remove oil filter element ⇒ Maintenance ; Booklet .
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Cop py
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co Vo
by lksw
cted agen
Prote AG.

– Disconnect electrical connector -1- on charge pressure sender
- G31- / intake air temperature sender - G42- and remove right
air pipe.

– Pull out oil dipstick slightly, unscrew bolt -1-.

– Press off clip -2- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
– Place drip tray for workshop crane - VAS 6208- under point of
separation.
– Remove coolant hose, loosen hose clip -1- for this.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
Note
AG. Volkswagen AG d
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♦ Renew gaskets, seals and O-rings. olksw
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♦ Hose connections and air intake pipes/hoses must oris be free of
e nte
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oil and grease when installing. aut
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♦ Renew bolts for the oil filter bracket.

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♦ Tighten bolts in 2 stages:

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spec
– First tighten upper left and lower right bolts.

es, in part or in w
t to the co
– Install dipstick guide tube ⇒ page 151 .

– Install oil filter element, replenish engine oil and check oil level
rrectness of i
⇒ Maintenance ; Booklet .
l purpos
– Replenish coolant in cooling system, change coolant if engine

oil cooler has been renewed ⇒ page 189 .
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mercia
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r
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Prote AG.
3. Oil filter, oil pressure switch
Specified torques
Stage Bolts Specified torque/turning further angle
1 -arrows- In diagonal sequence, 14 Nm
2 -arrows- Turn 90° further using diagonal se‐
quence
3.3 Removing and installing oil pressure

switch
Removing
– Remove crankcase breather hose -1-, press release buttons
for this.
– Unclip and remove electrical connector on the crankcase ven‐
tilation hose -1-.
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– Free vacuum hoses -arrows-. agen oes
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– Remove air pipe from air filter housing; release hoserised clip -3- nte
for this. ut
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– Unscrew bolt -2-, swing air pipe with inlet pipe to rear and pull
ce
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nl
it off from turbocharger.
pt
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– Unscrew bolts -2- and remove engine lifting eye -1-.
h re
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spec
– Disconnect electrical connector -arrow-.
es, in part or in w
t to the co
– Remove oil pressure switch - F1- .
Installing
rrectness of i
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Note
nf
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orm
Renew seal.
m
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Specified torque
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Components Specified torque

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Oil pressure switch - F1- . Cop 20 Nm py
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3.4 Checking oil pressure and oil pressure
switch
⇒ “3.4.1 Checking oil pressure”, page 172
⇒ “3.4.2 Checking oil pressure switch”, page 173
3.4.1 Checking oil pressure


AG. Volkswagen AG d
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Cabriolet 2012 ➤
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♦ Oil pressure tester - V.A.G 1342-
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ility
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spec
t to the co
rrectness o
cial p
f inform
mer
Procedure
atio
om
• Oil level OK.
n
c
i
or
n thi
e
• Engine oil temperature approx. 80°C

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Note
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The specified test values refer to an oil temperature of approx.
py by
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80°C. The oil pressure falls at higher oil temperatures. If the Prote
cted AG.
agen
specified values are not reached, check whether the oil temper‐
ature is too high for this test (>120°C).
– Remove oil pressure switch - F1- ⇒ page 172 .

– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch - F1- .
– Screw an old oil pressure switch into hole on oil pressure tester
- V.A.G 1342- to seal hole.
– Start engine.
• Oil pressure at idling speed: at least 0.6 bar.
• Minimum oil pressure at 2,000 rpm: 1.0 bar.
3.4.2 Checking oil pressure switch

♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
AG. Volkswagen AG d
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♦ Auxiliary measuring set - V.A.G 1594C- s
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Procedure
nf
ercia
or
• Oil level OK.
m
m
atio
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• Engine oil temperature approx. 80°C

o
n in
or c
thi
e
– Remove oil pressure switch - F1- ⇒ page 172 .

t
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f
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch.
– Screw oil pressure switch - F1- -item 2- into hole in oil pressure
tester.
– Connect brown line -1- of oil pressure tester to earth (–).
– Connect voltage tester - V.A.G 1527B- to battery
olks
wagepositive (+) es n
ot g
and oil pressure switch - F1- using auxiliary
db
y V cable from auxil‐ ua
ran
iary measuring set - V.A.G 1594C- .orise tee
th or
au
• LED should not light up. ss ac
ce
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nl
pt
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If LED lights up now, replace oil pressure switch - F1-
wit
, is n
⇒ page 172 .
h re
hole
spec
es, in part or in w
– Start engine.
t to the co
Note
rrectness of i
l purpos
Observe the oil pressure tester and LED while starting, since the
switching point of the oil pressure switch may already be excee‐
ded when starting.
nform
mercia
• LED should light up at 0.3…0.6 bar.
at
om
ion
c
in t
– If LED does not light up, replace oil pressure switch - F1-
or
his
e
⇒ page 172 .
at
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Balancer shaft module

⇒ “4.1 Assembly overview - balancer shaft module ”, page 176
⇒ “4.2 Removing and installing balance shaft module”,
page 178
4.1 Assembly overview - balancer shaft module
1 - Oil drain plug

❑ 30 Nm
❑ With captive seal rolled agen
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2 - Oil sump horis
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❑ Removing and installing ss a c
⇒ page 156
ce
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un
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an
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3 - Suction line
itte
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❑ Clean strainer if soiled.
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4 - Bolt
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❑ 9 Nm
spec
es, in part or in w
5 - Connection
t to the co
❑ To oil pump
6 - O-ring
rrectness of i
❑ Renew.
l purpos
7 - Oil pump
nform
ercia
⇒ page 161
m
❑ Before installing, check a

com
tion in
that the two dowel
r
te o
sleeves for centring oil

thi
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pump on balancer shaft

do
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module are fitted.

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8 - Drive shaft
Co
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❑ For oil pump.
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9 - Circlip
by lksw
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Prote AG.
❑ Must lie in base of
groove.
❑ Renew damaged or
over-tensioned circlip.
10 - Dowel sleeve
11 - Balancer shaft module
❑ Removing ⇒ page 178
❑ Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block
are fitted.
12 - Spur gear
❑ For balancer shaft.
13 - Bolt
❑ 20 Nm + turn 90° further
❑ Renew.

14 - Bolt
❑ 90 Nm + 90°
❑ With washer.
❑ Renew.
15 - Hub
❑ Renew. AG. Volkswagen AG d
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16 - Intermediate gear wheel d b ara
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❑ Renew. autho eo
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❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
s
ce
le
wear.
un
pt
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❑ Installation position: Part number must be visible.
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❑ Make sure thrust washer is seated correctly ⇒ page 178 .
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17 - Thrust washer
h re
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spec
❑ Renew.
t to the co
❑ Installation position ⇒ page 178 .
❑ To install intermediate gear wheel, secure to balancer shaft module with grease.
rrectne
18 - Crankcase
❑ With crankshaft
ss o
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❑ Crankshaft sprocket to oil pump drive
f inform
mer
19 - Bolt
atio
m
❑ M7 = 13 Nm + 90° further
o
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❑ M8 = 20 Nm + 90° further
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❑ Renew.
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❑ Observe tightening sequence.

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20 - Dowel sleeve Prote
cted AG.
agen
21 - Bolt
❑ 9 Nm
22 - Oil extraction pipe
23 - Bolt
❑ 9 Nm
24 - Bolt
❑ Renew.
4. Balancer shaft module 177

Thrust washer installation position
Caution

♦ When installing intermediate gear wheel, make sure that
thrust washer -A- does not slip out of balancer shaft mod‐ G. Volkswagen AG d
ule indentations -arrows- and subsequently become jam‐lkswagen A oes
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med. If necessary, fix in place with grease on balancer byV
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4.2 Removing and installing balance shaft d
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module
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⇒ “4.2.1 Removing balancer shaft module”, page 178
h re
ole,
spec
⇒ “4.2.3 Installing a new balancer shaft module”, page 182
t to the co
⇒ “4.2.2 Installing a previously used balancer shaft module
again”, page 179
4.2.1 Removing balancer shaft module
rrectne
ss o
cial p
f
inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure
– Pull oil dipstick out.
– Remove vibration damper ⇒ page 44 .
Caution
Risk of destruction due to toothed belt jumping.

♦ Only turn crankshaft in engine direction of rotation.
– Turn crankshaft at bolt for toothed belt sprocket until crank‐

shaft is at “TDC”.

– Lock crankshaft in position with crankshaft stop - T10050- .

• The markings on the toothed belt sprocket -2- and the crank‐
shaft stop -1- must align -arrow-. When doing this, the pin of
the crankshaft stop must engage in the drilling of sealing
flange.
Note
Crankshaft stop can only be pushed onto toothed belt sprocket

from face end of splines.

– Unscrew bolts in the sequence -8 … 1- or -6 ... 1- and remove
balancer shaft module together with oil pump.
Balancer shaft module with 8 threaded connection points
AG. Volkswagen AG d
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Balancer shaft module with 6 threaded connection points ss ce
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♦ ⇒ “4.2.3 Installing a new balancer shaft module”, page 182 .

, is n
h re
hole
♦ ⇒ “4.2.2 Installing a previously used balancer shaft module

spec
again”, page 179 .

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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4.2.2 Installing a previously used balancer

fo
en
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t.
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shaft module again
Co
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Special tools and workshop equipment required p by
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Prote AG.

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♦ Locking device - T10255- ris
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utho eo
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spec
t to the co
rrectne
♦ Bits - T10099-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Procedure
Caution
If the intermediate gear wheel bolt was loosened, the drive gear
wheel on the crankshaft was renewed or the crankshaft was
removed, a new intermediate gear wheel with coating must be
installed and the hub ⇒ Item 15 (page 177) with bolt
⇒ Item 14 (page 177) and thrust washers must be renewed.
Otherwise, the tooth backlash will be incorrect. Procedure
when installing ⇒ page 182 .
Note
♦ Proceed as follows if the previously used balancer shaft mod‐

ule is being reinstalled and neither the spur gear on the crank‐
shaft nor the crankshaft have been renewed. The intermediate
gear wheel must also not have been loosened.
♦ Replace bolts that are tightened with specified tightening an‐
gle.

– Lock balancer shaft with locking tool - T10255- ; if necessary,

turn balancer shaft.
• Locking tool pin must engage in groove in balancer shaft when
doing this.
– Insert dowel sleeves if no dowel sleeves for centring balancer
shaft module are fitted on cylinder block.
– Place balancer shaft module on cylinder block.
• The intermediate gear wheel must mesh in the crankshaft spur
gear when the balancer shaft is locked.
• The intermediate gear wheel must have a slight tooth back‐
lash.
– Tighten bolts of balancer shaft module as follows:
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
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Tightening sequence - balancer shaft module with 8 bolted con‐
du
an
itte
nection points
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Stag Bolts Specified torque
wit
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hole
1 -1- to -8- Hand-tighten in sequence
spec
es, in part or in w
2 -1- to -8- Initially tighten in sequence to 6 Nm
t to the co
3 -1- to -4- Tighten to 20 Nm
4 -5- Tighten to 13 Nm
rrectness of i
l purpos
nform
ercia
8 -1- to -8- Turn bolts 90° further in sequence

m
at
using a fixed wrench

om
ion
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or
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ate
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2 -1- to -6- Initially tighten in sequence to
6 Nm
4 -5- and -6- Tighten to 13 Nm
5 -1- to -6- Turn bolts 90° further in se‐
quence using a fixed wrench
– Remove crankshaft stop - T10050- .
– Install vibration damper ⇒ page 44 .

4.2.3 Installing a new balancer shaft module

♦ Locking device - T10255-
♦ Bits - T10099-
lkswage es n
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byV ua
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Procedure
h re
hole
spec
• Specified torques
es, in part or in w
⇒ “1.1 Assembly overview - sump / oil pump”, page 151 .

t to the co
• Crankshaft locked in position with crankshaft stop - T10050- .

rrectness of i
Note
l purpos
♦ The spur gear drive of the balancer shaft module must be in‐
nform
ercia
stalled with correct tooth backlash.

m
at
♦ A coating of correct thickness is applied to the new intermedi‐

om
ion
ate gear wheel to set the correct backlash. The coating is

c
in t
or
applied in part around the teeth.

his
ate
do
riv
♦ The coating is quickly worn away, which sets the correct back‐
p
cum
or
lash.
f
en
ng
t.
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♦ A new balancer shaft module must always be installed with a C py
t. rig
new intermediate gear wheel with coating.
gh ht
pyri by
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by
♦ Replace bolts that are tightened with specified tightening an‐ cted agen
Prote AG.
gle.

Caution

♦ To fit balancer shaft module, do not loosen intermediate
gear wheel bolt more than specified. Thrust washer in‐
stallation position ⇒ page 178
– Loosen bolt -1- for intermediate gear wheel approx. 45°.

– Insert dowel sleeves if no dowel sleeves for centring balancer
shaft module are fitted on cylinder block.
– Place balancer shaft module on cylinder block.
• Coating on intermediate gear wheel must not be damaged.

nection points
e
2 -1- to -8- Initially tighten in sequenceentoAG. Volkswagen AG
6 Nm olks
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3 -1- to -4- Tighten to 20 Nm rised b ara
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4 -5- Tighten to a13 ut Nm
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t to the co
nection points
rrectne

s
e
s o
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inform
mer
2 -1- to -6- Initially tighten in sequence to

atio
6 Nm
om
n
c

or
n thi
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sd
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4 -5- and -6- Tighten to 13 Nm

iv
o
pr
cum
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fo
en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Lock balancer shaft with locking tool - T10255- ; if necessary,

turn balancer shaft.
• Locking tool pin must engage in groove in balancer shaft when
doing this.
– Carefully fit balancer shaft gear wheel onto balancer shaft;

push intermediate gear wheel slightly to side for this.
• Coating on intermediate gear wheel must not be damaged.
• If possible, threaded holes of balancer shaft should be located
centrally in elongated holes of balancer shaft gear wheel.
Note
If elongated holes in balancer shaft gear wheel cannot be aligned

to threaded holes, balancer shaft gear wheel must be turned by
respective number of teeth and fitted again.
agen
AG. Volkswagen AG d
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b yV ua
– Tighten bolts -arrows- for balancer
ris
ed shaft gear wheel. ran
tee
tho or
u
– Remove locking tool - T10255-
ss
a . ac
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
The following 3 procedures must be performed simultaneously

(2nd mechanic required).
– Press intermediate gear wheel -3- forcefully (with assistance

of a wooden rod if necessary) in -direction of arrow- into spur
gear teeth -2- and balancer shaft gear wheel -1-.
– When doing so, turn balancer shaft gear wheel slightly anti‐
clockwise.
– Tighten bolt for intermediate gear wheel.
– Remove crankshaft stop - T10050- .
Note
No backlash may be perceptible after installing intermediate gear

wheel. This can be checked by hand using light force.

– Install vibration damper ⇒ page 44 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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f
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram”, page 186
⇒ “1.2 Checking cooling system for leaks”, page 187
⇒ “1.3 Draining and filling coolant”, page 189
1.1 Coolant hose schematic diagram
1 - Radiator
newing.
2 - Coolant circulation pump 2
- V178-
Caution
After fitting a new coolant
circuit pump, it is essen‐
tial to bleed the cooling
system using the VAS
6096 ⇒ page 189 . If this
is not done, air inclusions
can cause consequential
damage to the exhaust
gas recirculation cooler
as a result of overheat‐
ing.
3 - Engine oil cooler

AG. Volkswagen AG d
4 - 4/2-way valve with thermo‐ lksw
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not
stat d by Vo gu
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❑ Removing and installing thor eo
⇒ page 197 s au ra
c
s
ce
le
5 - Coolant pump
un
pt
an
d
itte
6 - Cylinder head and cylinder

y li
erm
ab
block
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wit
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newing.
h re
ole,
spec
7 - Coolant expansion tank

t to the co
❑ With cap
❑ Checking pressure re‐
lief valve in filler cap
rrectne
⇒ page 187 .
8 - Exhaust gas recirculation cooler
ss o
❑ Change coolant after renewing.

cial p
f inform
❑ Checking exhaust gas recirculation cooler for leaks ⇒ page 348

mer
atio
m
9 - Auxiliary heater
o
n
c
i
or
10 - Circulation pump - V55-

thi
te
sd
iva
11 - Heat exchanger for heater unit

pr
cum
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fo

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t.
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Cop py
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co lksw
by
cted agen
186
Prote AG.
Rep. gr.19 - Cooling
12 - Gear oil cooler

❑ For double clutch gearbox.
1.2 Checking cooling system for leaks

AG. Volkswagen AG d
agen oes
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WARNING byV gu
ara
ed
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ho eo
ut
When doing any repair work, especially
ss a in the engine compart‐ ra
c
ce
le
un
tions:
pt
an
d
itte
y li
rm
ab
pe
restored.
ility
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wit
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hot components.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ When the engine is warm, the cooling system is under pres‐
l purpos
sure. If necessary, release pressure before beginning repair

work.
nform
ercia
♦ Hoses are secured with spring-type clips. In case of repair,

m
a
only use spring-type clips.
com
tion in
♦ Hose clip pliers - VAS 6340- are recommended to install
r
te o
thi
spring-type clips.
s
iva
do
r
rp
cum
♦ When installing coolant hoses, route stress-free so that they
fo
en
g
do not come into contact with other components (observe

n
t.
yi Co
markings on coolant connection and hose). Cop py
ht. rig
rig ht
py by
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Test for leaks in cooling system using cooling system tester -
by c lksw
cted agen
V.A.G 1274/- and adapter for expansion tank - V.A.G 1274/8- and
Prote AG.
adapter for sealing cap - V.A.G 1274/9- .

♦ Cooling system tester - V.A.G 1274 B-
1. Cooling system, coolant 187

♦ Adapter for cooling system tester - V.A.G 1274/8-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
ss c
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nl
pt
du
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ility
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Test prerequisite
h re
hole
• Engine at operating temperature.
spec
es, in part or in w
t to the co
Test sequence:
WARNING
rrectness of i
l purpos
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
nf
ercia
orm
m
– Open filler cap on coolant expansion tank.
atio
om
n in
c
– Screw adapter for cooling system tester - V.A.G 1274/8- into

or
thi
coolant expansion tank.
te
sd
iva
o
r
rp
cu
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling

o
m
f
system tester - V.A.G 1274/8- .

en
ng
t.
yi Co
op py
– Join connection piece - V.A.G 1274 B/1- to cooling system t. C rig
gh ht
tester - V.A.G 1274 B- using connecting hose supplied. yri
p by
o Vo
by c lksw
cted
– Using hand pump on tester, build up a pressure of approx. 1.0
agen
Prote AG.
bar.
DANGER!
Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from the connecting hose or connector - V.A.G
1274 B/1- , it is essential that the pressure is relieved. To do
this, press pressure relief valve on cooling system tester -
V.A.G 1274 B- until pressure gauge displays value of »0«.
If pressure drops:
188 Rep. gr.19 - Cooling

– Search for leaks within engine compartment and on underside

of vehicle, remove noise insulation if required.
If no leaks are found:
– Check exhaust gas recirculation cooler for leaks
⇒ page 348 .
Check pressure relief valve in cap.
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Create a pressure (refer to following vehicle/engine combina‐
tion table for max. specified value) using hand pump for cool‐
ing system tester.
CFFA CFFB CFHC CFGB CLLA
Golf Cabrio --- --- 1.4 bar --- ---
CC 1.4 bar 1.4 bar --- 1.6 bar 1.6 bar
The pressure relief valve must not open.

swage es n
If the pressure relief valve opens prematurely: by Vo lk ot g
ua
d ran
ir se
– Renew cap. tho tee
or
au ac
– Increase pressure. ss
ce
e
nl
pt
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The pressure relief valve must open once the opening pressure
an
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is exceeded.
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If the pressure relief valve does not open:
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– Renew cap.
h re
hole
spec
1.3 Draining and filling coolant
es, in part or in w
t to the co
rrectness of i
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nform
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at
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c
in t
or
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ate
do
priv
cum
for
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AG. Volkswagen AG d
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Special tools and workshop olksw not
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♦ Refractometer - T10007 A- s au ra
c
s
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un
pt
- VAS 6208-
an
d
itte
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erm
ab
♦ Hose clip pliers - VAS
ility
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6340-
wit
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h re
♦ Cooling system charge unit
ole,
spec
- VAS 6096-
t to the co
♦ Adapter for cooling system
tester - V.A.G 1274/8-
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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t.
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by
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Prote AG.
WARNING

tions:
restored.
hot components.

Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
swage es n
Test for leaks in cooling system using cooling byV
o system tester -
lk ot g
ua
V.A.G 1274/- and adapter for expansion ir se tank - V.A.G 1274/8- and
d ran
tee
adapter for sealing cap - V.A.G 1274/9-
utho . or
a ac
ss
1.3.1 Draining
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nl
pt
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WARNING
ility
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Steam may escape when expansion tank is opened. Cover the
h re
cap with a cloth and open it carefully.
hole
spec
es, in part or in w
t to the co
– Open filler cap on coolant expansion tank.
– Remove noise insulation: ⇒ General body repairs, exterior;
rrectness of i
sulation .
l purpos
– Pull coolant hoses -1- off coolant circulation pump 2 - V178-
nform
ercia
-2-.
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at
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c
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ate
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for
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pyri by
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by
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Prote AG.
– Unlock the retaining clip -arrow- and remove the coolant hose
from the quick-release coupling on the radiator for the charge-
air cooling circuit.

– Unlock retaining clip -arrow- for the coolant hose and pull the
coolant hose off the quick-release coupling of the radiator.
AG. Volkswagen AG d
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olksw not
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au ra
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nl
pt
du
an
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ab
ility
ot p
wit
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– In addition to draining coolant from engine, pull the coolant
hole
hose off the engine oil cooler -arrow-.
spec
es, in part or in w
t to the co
Note
rrectness of i
Observe environmental regulations for disposal.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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t. rig
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by
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Prote AG.

lkswage es n
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byV CC 2012 ua ➤ , Golf Cabriolet 2012 ➤
d ran
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4-cylinder diesel
th engine (2.0 l engine, common rail, generation
o tee
or II) - Edition 09.2013
au ac
ss
1.3.2 Filling
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nl
pt
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Note
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♦ The amount of water used in the coolant mixture has a great hole
spec
influence on its effectiveness. Because the water quality dif‐
es, in part or in w
fers from country to country and even region to region, the
t to the co
quality of the water to be used has been defined. Distilled wa‐
ter fulfils all requirements. For this reason, we recommend
using distilled water when mixing coolant for topping up or re‐
rrectness of i
placing coolant.
l purpos
♦ Use only coolant additives in accordance with the ⇒ Electronic

Parts Catalogue (ETKA) . Other coolant additives may reduce
corrosion protection substantially. The resulting damage could
nf
ercia
o
lead to loss of coolant and subsequent severe damage to the
rm
m
engine.
atio
om
n in
c
♦ The correct coolant solution ratio helps prevent damage from

or
thi
e
freezing and corrosion as well as scaling. Moreover, the boil‐

t
sd
iva
ing temperature is raised. Therefore, the cooling system must
o
r
rp
cu
be filled all year round with coolant additive.
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♦ Because of its higher boiling point, the coolant improves en‐ Cop py
gine reliability under heavy loads, particularly in countries with
t. rig
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tropical climates. cop Vo
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♦ ONLY refractometer - T10007A- may be used for determining
AG.
current anti-freeze value.

♦ Frost protection must be guaranteed down to -25°C, and in
countries with arctic conditions down to -36°C. Increasing the
frost protection is only permissible if climatic conditions require
a stronger frost protection. However, it may be increased only
to a maximum of -48°C. Otherwise, the cooling effect will be
impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished anti-
freeze.
♦ The temperature read off the refractometer - T10007A- equa‐
tes to the »ice flocculation point«. Flakes of ice can start
forming in the coolant below this temperature.
♦ Do not reuse old coolant.
♦ Use only a water/anti-freeze mixture as a slip agent for coolant
hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost protection Anti-freeze Coolant ad‐ Distilled wa‐
to proportion ditive 1) ter 1)
-25°C 40% 3.2 l 4.8 l
-36°C 50% 4.0 l 4.0 l
1)The quantity of coolant can vary depending on the vehicle
equipment.

AG. Volkswagen AG d
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olksw not
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d by ara
CC 2012 ➤ , Golf Cabriolet 2012 ➤ orise nte
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4-cylinder diesel engine (2.0 l engine, common rail,augeneration
t II) - Edition 09.2013 ra
c
ss
ce
le
– Install lower coolant hose and secure it with the retaining clip
un
pt
an
d
-arrow-.
itte
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erm
ab
ility
ot p
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spec
t to the co
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f
– Install coolant hose on the radiator for the charge-air cooling
inform
circuit and secure it with the retaining clip-arrow-.
mer
atio
m
– Connect coolant hoses on the engine oil cooler and the coolant
o
n
c
circulation pump 2 - V178- .
i
or
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With cooling system charge unit - VAS 6096- t. C rig
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– Screw adapter for cooling system tester - V.A.G 1274/8- onto
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cted
expansion tank.
agen
Prote AG.
– Fill coolant circuit using cooling system charge unit -

VAS 6096- ⇒ Operating instructions for cooling system charge
unit VAS 6096 .
Without cooling system charge unit - VAS 6096-
– Slowly fill coolant in up to upper marking of hatched field on

expansion tank.
– Fit expansion tank cap.
– Start engine. Keep engine speed at approx. 2,000 rpm for
about 3 minutes.
– Then run engine at idling speed until radiator fan starts.
– Check coolant level and top-up if necessary. When the engine
is at normal operating temperature, the coolant level must be
at the upper mark; when the engine is cold, in the middle of
the hatched field.

swage es n
2 Coolant pump, regulation of cooling
olk ot g
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autho system tee
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⇒ “2.1 Assembly overview - coolant pump, thermostat”,
ce
le
un
page 195
pt
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⇒ “2.2 Removing and installing coolant pump”, page 196
erm
ab
ility
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⇒ “2.3 Removing and installing 4/2-way valve with thermostat”,
wit
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page 197
h re
ole,
spec
⇒ “2.4 Electric coolant pump”, page 202
t to the co
⇒ “2.5 Removing and installing coolant temperature sender”,
page 206
rrectne
2.1 Assembly overview - coolant pump, thermostat
ss o
1 - Coolant pump
cial p
f in
form
mer
⇒ page 196
atio
om
2 - 15 Nm
n
c
i
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3 - O-ring
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❑ Renew.
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4 - O-ring
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5 - 4/2-way valve with thermo‐
by lksw
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stat
AG.
❑ The thermostat is loca‐

ted within the 4/2-way
valve and cannot be ex‐
changed individually.
⇒ page 197
6 - 15 Nm
2. Coolant pump, regulation of cooling system 195

2.2 Removing and installing coolant pump

equipment required
♦ Refractometer - T10007 A-
♦ Torque wrench (5…50 Nm)
- V.A.G 1331-
6340-
AG. Volkswagen AG d
agen oes
olksw not
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Removing
wit
is n
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spec
Note
t to the co
Renew gaskets and seals.

rrectne

ss o
cial p

inform
mer
atio
om
n
c
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fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

– Remove coolant pump securing bolts -1- and carefully remove

coolant pump -2-.
Installing
– Coat new O-ring -3- with coolant.

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– Insert coolant pumpksw
-2-
ageninto
AG cylinder eblock
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and
oes tighten securing
bolts -1-. by
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The coolant pump plug faces downwards.
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ility
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h re
hole
– Replenish coolant ⇒ page 189 . spec

es, in part or in w
t to the co
Specified torque
rrectness of i

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Coolant pump to cylinder block 15 Nm

nform
ercia
2.3 Removing and installing 4/2-way valve

m
at
om
io
with thermostat
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ate
do
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Note
f
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op
The thermostat is located within the 4/2-way valve and cannot be
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replaced individually.
rig ht
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Prote AG.


equipment required
♦ 10 mm jointed spanner -
3185-
♦ Allen key, long reach -
T10058-
1331/-
- VAS 6208-
6340-
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a ac
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nl
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hole
spec
es, in part or in w
t to the co
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Removing
nform
mercia
Note
at
om
ion
c
in t
or
Renew gaskets and seals.

his
ate
do
priv
cum

for
en
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t.
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Co
Cop py
t. rig
gh ht
– Remove air filter housing with air mass meter and connecting yri
p by
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pipe ⇒ page 289 .
c by lksw
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Prote AG.

– Remove battery carrier by unscrewing securing bolts

-arrows-.

er. To do this, press release buttons.
– Free vacuum hoses -arrows- at air pipe.
AG. Volkswagen AG d
agen oes
lksw not
– Unscrew bolt -2-, swingd byair pipe with inlet connection to rear
Vo gu
ara
and remove it fromorithe
se turbocharger. nte
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aut ra
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nl
pt
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ab
ility
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spec
es, in part or in w
t to the co
– Unclip wiring harness from bracket -arrow-.

rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
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Cop py
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by c lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
CC 2012 ➤ , Golf Cabriolet
autho
2012 ➤ eo
ra
s (2.0 l engine, common rail, generation II) - Edition
s c
09.2013
ce
le
un
pt
an
d
– Clear away wiring harnesses -arrows- and electrical connector
itte
y li
-1- from bracket.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Clear away electrical wiring and hoses on left air pipe using
o
n
c
removal lever - 80 - 200- .
i
or
n thi
te
sd
a

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pr
cum
r
fo
en
ng
t.
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t. rig
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cted agen
Prote AG.
– Pull off coolant hoses. To do this, release hose clips -1-.
– Remove electrical connector -1- for Hall sender - G40- from

bracket.
– Unscrew bolts -arrows-, pull front coolant pipe to one side
away from 4/2-way valve.

– Pull coolant pipe out of connection -C- for 4/2-way valve.

Leave at its install position.
– Unscrew the screws -arrows-.

- G31- / intake air temperature sender - G42- and remove right
air pipe.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
AG. Volkswagen AG d
agen oes
olksw not
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– Unscrewabolt
ut
h -1-. ra
ss c
– Press off clip -2- using removal lever - 80 - 200- .
ce
le
un
pt
an
d
– Pull oil dipstick guide tube off cylinder block upwards and push
itte
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erm
to side.
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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t.
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CC 2012 ➤ , Golf Cabriolet 2012 ➤ olkswagen AG
en AG. V
olks
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no
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– Pull coolant hoses off connections rise -A, B and D-. nte
tho eo
au ra
– Unscrew securing bolts -3- sfor 4/2-way valve -2-.
s c
ce
e
nl
pt
– Pull out valve from cylinder block.
du
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Installing
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ility
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Installation is carried out in the reverse order. When installing,
wit
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note the following:
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spec
es, in part or in w
t to the co
rrectness of i
– Moisten new O-ring -1- with coolant.
l purpos
Specified torques ⇒ page 195 .
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
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by
cted agen
2.4 Electric coolant pump
Prote AG.
⇒ “2.4.1 Assembly overview - electric coolant pump”, page 202

⇒ “2.4.2 Removing and installing electric coolant pump”,
page 204
2.4.1 Assembly overview - electric coolant pump

1 - Bolt
❑ 1.5 Nm
❑ Qty. 3
2 - Rubber grommet with
sleeve
❑ Qty. 3
3 - Bolt
❑ M6 x 12
❑ 8 Nm
4 - Bracket
5 - Bolt
❑ 40 Nm
6 - Coolant circulation pump 2
- V178-
⇒ page 204
7 - Coolant hose
❑ Water hoses schematic AG. Volkswagen AG d
diagram ⇒ page 186 lksw
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not
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8 - Coolant hose rised ara
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❑ Water hoses schematic aut
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diagram ⇒ page 186 ss c
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spec
t to the co
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mer
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n
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t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

2.4.2 Removing and installing electric coolant pump

equipment required
- VAS 6208-
6340-
♦ Cooling system charge unit
- VAS 6096-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
AG. Volkswagen AG d
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spec
t to the co
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mer
atio
om
n
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♦ Hose clamps up to 40 mm - 3093-

sd
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

Removing
WARNING

sure.
Cover filler cap on expansion tank with a cloth and open care‐

sulation .
– Remove air hose, loosen hose clips -1- and -2- for this.
AG. Volkswagen AG d
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WARNING
an
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ab
ility
Danger of injury; the radiator fans can run at any time.
ot p
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♦ Even if ignition is switched off, radiator fans can run at any
h re
hole
time, e.g. because of accumulated heat in the engine
spec
compartment.
es, in part or in w
t to the co
rrectness of i
– Undo hose clip -2- and push right air duct to right.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note
Place a cloth underneath coolant circulation pump 2 - V178- to

absorb escaping coolant.
– Clamp off coolant hoses with hose clamps -3094- and remove;
to do this, loosen hose clips -3-.
– Disconnect electrical connector -2-.
– Undo bolt -1- and remove coolant circulation pump 2 - V178- .
Installing
Note

to original equipment ⇒ Electronic Parts Catalogue (ETKA) . agen
AG. Volkswagen AG d
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– Install air pipe. rised
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– Installing intake hoses with screw-type clips. ss a ra
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un
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– Check coolant level ⇒ page 189 .
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Specified torques
spec
t to the co
Coolant circulation pump 2 - V178- on the bracket 1.5 Nm
rrectne
Bolts M10 on the engine 40 Nm
ss o
cial p
f
2.5 Removing and installing coolant temper‐
inform
mer
ature sender atio

om
n
c
⇒ “2.5.1 Removing and installing coolant temperature sender G62

i
or
n thi
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”, page 206
t
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pr
⇒ “2.5.2 Removing and installing coolant temperature sender at

um
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fo
radiator outlet G83 ”, page 208

en
ng
t.
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2.5.1 Removing and installing coolant temper‐
t. C rig
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ature sender - G62-
op Vo
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Prote AG.

Removing
• Engine cold
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
sulation .
– Pull off crankcase breather hose -1- from cylinder head cover
by pressing the release buttons.
– Unclip and remove plug on the crankcase ventilation hosen AG. Volkswagen AG do
-1-. wage es n
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– Free vacuum hoses -arrows- at air pipe. rise nte
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– Unscrew bolt -2-, swing air pipe with inlet
s au pipe to rear and re‐
ra
c
s
move from turbocharger.
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un
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an
d
itte
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erm
ab
ility
ot p
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spec

t to the co
– Pull off coolant hoses from gear oil cooler by undoing hose
clips -arrows-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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t.
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AG. Volkswagen AG d
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– Remove bolt -arrows-. olksw not
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lever - 80 - 200- . s aut ra
c
s
– Loosen hose clip -3- and press left air pipe with coolant pipe
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un
pt
aside.
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pe
ility
ot
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spec
es, in part or in w
t to the co
– Unlock and pull connector -4- off coolant temperature sender
- G62- .
rrectness of i
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Note
♦ Place a cloth under connecting piece to absorb escaping cool‐
nform
ercia
ant.
m
a
com
t
♦ Insert new coolant temperature sender - G62- immediately in‐
ion in
to union to avoid loss of coolant.
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Note
♦ Renew O-ring.
to union to avoid loss of coolant.
2.5.2 Removing and installing coolant temper‐

ature sender at radiator outlet - G83-
Removing
• Engine cold
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.
Note
♦ Place a cloth under coolant temperature sender at the radiator

outlet - G83- to absorb escaping coolant.
to coolant pipe at radiator outlet to avoid loss of coolant.

– Undo bolt -1-.

– Unscrew bolt -2- and nut -3-.
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
– Release and pull connector -2- off radiator outlet coolant tem‐
perature sender - G83- .
– Pull off retaining clip -4- and pull coolant temperature sender
at radiator outlet - G83- out of screw connection of coolant
agen
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3 Coolant pipes
⇒ “3.1 Assembly overview - coolant pipes ”, page 210
⇒ “3.2 Removing and installing coolant pipes”, page 211
3.1 Assembly overview - coolant pipes
1 - Grommet
❑ Not available as a sepa‐
rate part.
2 - Sleeve
❑ Not available as a sepa‐
rate part.
3 - 2.7 Nm
4 - 40 Nm
5 - Bracket
❑ For coolant circulation
pump 2 - V178-
6 - Front coolant pipe
⇒ page 211
AG. Volkswagen AG d
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12 - Radiator outlet coolant

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temperature sender - G83-

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⇒ page 208
rrectness of i
13 - 9 Nm
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14 - 9 Nm
15 - 9 Nm
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16 - Coolant line
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17 - Gasket
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20 - Coolant temperature sender - G62-
21 - Centre hex stud, 9 Nm
❑

22 - 9 Nm
23 - Retaining clip
24 - Left coolant pipe
25 - 9 Nm
26 - 9 Nm
27 - 9 Nm
28 - 13 Nm
29 - Upper front coolant pipe
30 - Coolant circulation pump 2 - V178-
Caution
After fitting a new coolant
circuit pump, it is essen‐
tial to bleed the cooling
system using the VAS
6096 ⇒ page 189 . If this
is not done, air inclusions
can cause consequential
damage to the exhaust
gas recirculation cooler
as a result of overheat‐
ing. wage
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3.2 Removing and installing coolant pipes
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⇒ “3.2.1 Removing and installing front coolant pipe”, page 211

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⇒ “3.2.2 Removing and installing upper front coolant pipe”,

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⇒ “3.2.3 Removing and installing left coolant pipe”, page 216

spec
es, in part or in w
⇒ “3.2.4 Removing and installing right coolant pipe”, page 218

t to the co
3.2.1 Removing and installing front coolant

pipe
rrectness of i
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3. Coolant pipes 211

♦ Hose clamps, up to 25 mm - 3094- for vehicles with dual clutch

gearbox
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– Unscrew bolts -arrows- and remove battery support -1-.

hole
spec
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er. To do this, press release buttons.

rrectness of i
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– Expose vacuum hoses -arrows- at air pipe.

– Unscrew bolt -2-, swing air pipe with inlet connection to rear
– Unclip wiring harness from bracket -arrow-.
Vehicles with dual-clutch gearbox:

– Clamp off coolant hoses with hose clamps -3094- and pull
them off gear oil cooler. To do this, loosen hose clamps
-arrows-.
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3. Coolant pipes
– Remove air hose. To do this, loosen hose clamps -1- and

-2-.
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– Undo hose clamps -1- and pull off coolant hoses.
ion in
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– Remove electrical connector -1- for Hall sender - G40- from

bracket.
– Remove bracket from front coolant pipe.

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– Undo hose clamps -2- -3- and pull off coolant hoses.
s
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– Unscrew bolts -arrows- and pull front coolant pipe out of 4/2-
an
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♦ Renew gaskets, seals and O-rings.
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– Push front coolant pipe into 4/2-way valve.
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3.2.2 Removing and installing upper front

coolant pipe

Removing
– Unscrew bolt -2-.
– Loosen hose clamps -1- -3- and pull coolant hoses off.
– Remove top coolant pipe at front.
Installing
3.2.3 Removing and installing left coolant pipe

AG. Volkswagen AG d
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– Clear away wiring harnesses -arrows- and the electrical con‐
nector -1- from bracket. t to the co

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– Unscrew bolts -2- and -5- -arrow-.

lever - 80 - 200- .
– Place drip tray for workshop crane - VAS 6208- beneath en‐
gine.
– Clamp off coolant hoses with hose clamps -3094- and undo
hose clamps -1- and -4-.
– Pull coolant hoses off left coolant pipe.

– Remove left coolant pipe.
Installing
• Specified torques: ⇒ page 210 .
Note

– Electrical connections and routing ⇒ Current flow diagrams, AG. Volkswagen

Electrical fault finding and Fitting locations. lksw
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♦ Drip tray for workshop hoist - VAS 6208- ksw
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Removing
co Vo
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– Undo bolt -1- and unscrew bolt -2- and nut -3-.
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
sulation .

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– Place drip
au tray for
th workshop crane - VAS 6208- beneathoren‐
a
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gine. ss c
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– Pull connector -3- off radiator outlet coolant temperature send‐
du
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– Undo hose clamps -arrows- and pull coolant hoses off right
coolant pipe.
nform
ercia
– Remove nut -1- and bolt -2- and remove right coolant pipe.
m
at
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Secure all hose connections with the hose clips corresponding to
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original equipment ⇒ Electronic Parts Catalogue (ETKA) . Prote AG.

4 Radiator/radiator fan
⇒ “4.1 Assembly overview - radiator/radiator fan”, page 221
⇒ “4.2 Removing and installing radiator”, page 222
⇒ “4.3 Removing and installing radiator cowling with radiator fan”,
page 223
⇒ “4.4 Removing and installing radiator fan”, page 224
4.1 Assembly overview - radiator/radiator fan
1 - Radiator/cooler
⇒ page 222
❑ After renewing, renew
entire coolant.
2 - O-ring
❑ Renew if damaged.
3 - Upper coolant hose
4 - Cap
❑ Check using cooling
system tester - AG. Volkswagen AG d
V.A.G 1274- and adapt‐ agen oes
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⇒ page 187 . ho ris nte
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5 - Connector ss
ce
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nl
6 - 5 Nm
pt
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7 - Expansion tank
erm
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tem for leaks with cool‐

h re
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spec
V.A.G 1274- and adapt‐

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er - V.A.G 1274/8-
t to the co
⇒ page 187 .
8 - Lower coolant hose
rrectness of i

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9 - 5 Nm
nform
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10 - 5 Nm
m
at
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11 - Radiator fan - V7-

ion
c
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12 - Right radiator fan - V35-

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13 - Connector
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14 - Radiator cowl
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4. Radiator/radiator fan 221

4.2 Removing and installing radiator

equipment required
1331/-
6340-
AG. Volkswagen AG d
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Removing
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noise insulation .
h re
hole

spec
es, in part or in w
t to the co
– Remove radiator cowl with radiator fan ⇒ page 223

– Release retaining clip -arrow-.
rrectness of i
– Pull off coolant hose -1- from top of radiator.

l purpos
nform
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at
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c
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Rep. gr.19 - Cooling Prote
cted AG.
agen
– Unlock retaining clip -arrow- for the coolant hose and pull the
coolant hose off the right quick-release coupling of the radia‐
tor.
– Remove radiator securing bolts -arrows- and take out radiator

upwards.
Installing
Specified torques
Radiator to charge air cooler 5 Nm
Radiator cowl on radiator 5 Nm
AG. Volkswagen AG d
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4.3 Removing and installing radiator cowl‐ y V gu
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Removing
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– Remove noise insulation ⇒ General body repairs, exterior; ab

ility
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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐ wit

is n
sulation .
h re
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spec
– Pull cover off air duct by releasing retaining clips at sides

-arrows-.
t to the co
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cial p
f inform
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atio
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– Unclip lower air duct -2- by releasing retaining clips on left and
right -arrow A-.
– Unclip air duct at mountings -3-. In order to do so, swing air
duct downwards and slightly to rear.
– Detach air pipe -1- from lower air duct -arrow B-.
– Unscrew bolts -arrows- from lock carrier and remove the air
duct.
pipe ⇒ page 289 .
AG. Volkswagen AG d
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– Remove cowling together with radiator fans upwards.

h re
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Installing
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Specified torque
mer
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Radiator cowl on the radiator 5 Nm

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noise insulation .

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– Remove radiator cowl with
Vol
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wa fan ⇒ page 223 . not
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– Uncover cables -1-.
or
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– Unscrew nutsss a-arrows- and remove fan. c
ce
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Installing
un
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wit
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grams, Electrical fault finding and Fitting locations.
h re
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t to the co
rrectne
Specified torques
s
s o
cial p
f i
Radiator fan on radiator cowl 10 Nm
nform
mer
Radiator cowl on radiator 5 Nm
atio
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21 – Turbocharging/supercharging
1 Turbocharger
⇒ “2 Safety instructions”, page 3
⇒ “1.1 Assembly overview - turbocharger .”, page 226
⇒ “1.2 Removing and installing turbocharger”, page 229
⇒ “1.3 Renewing vacuum unit for turbocharger”, page 234
1.1 Assembly overview - turbocharger .
Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil supply line, fill turbocharger at connec‐
tion with engine oil.
♦ After installing turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
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Prote AG.
Rep. gr.21 - Turbocharging/supercharging
1 - Exhaust gas recirculation

pipe
❑ With flexible joint; do not
bend flexible joint - dan‐
ger of cracking.
2 - Gasket
❑ Renew.
3 - 17 Nm
❑ Renew.
4 - Oil supply line
❑ Check for continuity.
❑ Before installing, fill tur‐
bocharger with engine
oil at oil supply line con‐
nection.
❑ Tighten union nuts to
22 Nm.
5 - Oil return line
6 - Gasket
❑ Renew.
7 - 24 Nm
8 - Heat shield
9 - Turbocharger
AG. Volkswagen AG d
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⇒ page 229
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❑ Renew. t to the co
12 - Pulsation damper
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13 - 9 Nm
l purpos
14 - Intake connecting pipe

15 - 9 Nm
nform
ercia
❑ Attached in inlet connection.

m
16 - O-ring
com
tion in
❑ Renew.
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17 - Bracket
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18 - 15 Nm C py
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19 - Heat shield
py by
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20 - Gasket
Prote AG.
❑ Renew.
21 - 24 Nm
❑ Renew.
1. Turbocharger 227
22 - Exhaust gas temperature sender 1 - G235-

❑ Assembly overview ⇒ page 337 .
23 - 20 Nm
24 - Support
❑ For turbocharger
25 - 9 Nm
26 - O-rings
❑ Various diameters.
❑ Renew.
27 - Banjo bolt; 40 Nm
❑ Renew.
AG. Volkswagen AG d
28 - O-rings ksw
agen oes
not
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❑ Renew. d by gu
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29 - Banjo bolt; 30 Nm auth eo
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30 - O-rings
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❑ Renew.
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31 - 24 Nm
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228 Rep. gr.21 - Turbocharging/supercharging

1.2 Removing and installing turbocharger

equipment required
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♦ Lambda probeVoopen ring
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♦ Ratchet
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t or
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♦ Tool set, 17 mm - T10395-
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♦ Transport guard - T10404-
ility
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1. Turbocharger 229
Removing
Note
♦ Fit heat shield sleeve in the same place when installing.

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gen AG
♦ Seal off all exposed openings of the kexhaust turbocharger with
swa oes d
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engine bung set - VAS 6122-ed.by gu
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♦ All hose connections areauthsecured. eo
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♦ Charge air system must be free of leaks.
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♦ Before screwing on oil supply line, fill turbocharger at connec‐
ility
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tion with engine oil.
wit
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♦ After installing turbocharger, run engine for about 1 minute at
hole
spec
idling speed to ensure that oil is supplied to turbocharger.
es, in part or in w
t to the co
– Observe rules for cleanliness ⇒ page 6 .
rrectness of i
Caution
l purpos
If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just renew
nform
ercia
the turbocharger. To avoid any subsequent damage, the fol‐

lowing work must be carried out:
m
at
om
ion
c
♦ Check air filter housing, air filter element and air inlet ho‐
in t
or
ses for contamination. his

ate
do
riv
♦ Check the whole charge air path and charge air cooler for
p
cum
or
foreign objects.
f
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♦ If foreign objects are discovered in the charge air system,
C py
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clean the charge air path and, if necessary, renew the
ht
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charge air cooler.
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– Remove particulate filter ⇒ page 311 .
Disconnecting and connecting battery .
– Remove battery carrier, unscrewing securing bolts -arrows- to
do so.

– Remove crankcase breather hose -1- from the cylinder head

cover by pressing the release buttons.
-1-.
off from turbocharger.
– Remove heat-shield sleeve.
– Pull vacuum hose -2- from turbocharger vacuum unit.

– Disconnect electrical connector -1- at position sender for
charge pressure positioner - G581- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
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pt
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– Free electrical connector -1- for exhaust temperature sender

erm
ab
ility
1 - G235- and electrical line.

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es, in part or in w
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1. Turbocharger 231
Vehicles with dual clutch gearbox

– Pull off coolant hoses from gear oil cooler, loosen hose clips
-arrows- for this.

– Take off pulsation damper -2-.

– Expose electric cable.
– Remove exhaust gas temperature sender 1 - G235- -1-
⇒ page 338
AG. Volkswagen AG d
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un
pt
an
d
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– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
y li
rm
ab
lation.
pe
ility
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es, in part or in w
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232
AG.
Rep. gr.21 - Turbocharging/supercharging
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line. wagen AG. Volkswagen AG doe
ks s no
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es, in part or in w
t to the co
– Unscrew bolts -arrows- and remove heat shield.
rrectness of i
l purpos
nform
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at
om
ion
c
in t
or
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ate
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– Unscrew nuts -arrows- and pull turbocharger with exhaust Cop py
manifold off cylinder head.
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Installing
lksw
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Prote AG.
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
♦ Fit heat shield sleeves in the same place when installing.
– Installing intake hoses with screw-type clips ⇒ page 242 .

– Install exhaust gas recirculation pipes ⇒ page 344 .
– Connect vacuum hoses ⇒ page 284 .
– Install air filter housing ⇒ page 289 .
– Install particulate filter ⇒ page 311 .
1. Turbocharger 233
Specified torques
AGR pipes ⇒ “5 Exhaust gas recirculation”, page 344
Particulate filter ⇒ “2.1.1 Assembly overview - front exhaust pipe with particulate filter”,
page 307
Turbocharger ⇒ “1.1 Assembly overview - turbocharger .”, page 226
Exhaust gas temperature sender ⇒ “4.2 Removing and installing parts of exhaust gas temperature regula‐
tion”, page 338
Coolant pipe to engine 9 Nm
1.3 Renewing vacuum unit for turbocharger

♦ 10 mm socket insert - T10422 A-
AG. Volkswagen AG d
agen oes
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♦ Ring spanner 10x12 - T10423-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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♦ Hand vacuum pump - VAS 6213-

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♦ Engine bung set - VAS 6122-
♦ Vehicle diagnostic tester
Caution
The special tools indicated, in particular the 10AF socket inset,

- T10422 A- is designed solely for use according to the follow‐
ing work instructions and must not be used for other threaded
connections. There is a danger of deformation if high torques
are applied.
Note
In order to replace the vacuum unit with position sender for charge
pressure positioner, - G581- a spare-parts kit is available ⇒ Elec‐
tronic Parts Catalogue (ETKA) .
Removing
– Open heat-protection mat and disconnect Aelectrical
G. Volkswaconnector
gen AG
-arrow- at position sender for charge agen
kswpressure positioner - es not
do
ol
G581- . ed
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es, in part or in w
t to the co
– Remove crankcase breather connecting pipe-1- from cylinder

head cover; press release buttons to do this.
rrectness of i

l purpos
-1-.
– Free vacuum hoses -arrows-.
nform
ercia
– Unscrew bolt -2- (captive), swing air pipe with inlet pipe to rear
m

a
com
tion in
– Seal opening in turbocharger with sealing cap from engine

r
te o
thi
bung set - VAS 6122- .

s
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– Pull vacuum line off vacuum unit.

um
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1. Turbocharger
agen
Prote AG.
– Hold lock nut -B- and unscrew securing nut -A- from the control
rod with 10 AF socket - T10422 A- .
– Unscrew securing bolts of the vacuum unit -arrows- and re‐

move the vacuum unit with position sender for charge pres‐
sure positioner - G581- -A-.
Installing
Caution
Only use new bolts and nuts from the spare-parts kit!
– If necessary, remove lower securing nut of the control rod from

the new vacuum unit.
– Screw locknut by hand onto the control rod as far as possible
in the direction of the vacuum unit.
– Push control rod through the adjusting lever, fit vacuum unit
with position sender for charge pressure positioner - G581-
-A- and tighten fastening bolt.
– Tighten securing bolts -arrows- to 8 Nm.
AG. Volkswagen AG d
agen oes
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Make sure that the guiding element moves easily along the scon‐
s a c
trol rod.
ce
le
un
pt
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d
itte
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rm
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ility
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, is n
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hole
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es, in part or in w
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rrectness of i
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tion in
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– Connect connector -arrow- to the position sender for the

charge pressure positioner - G581- and close the heat pro‐
tection mat.
– Connect vehicle diagnosis tester .
Selecting operating mode:
– Click the “Vehicle self-diagnosis” button on the display.
Selecting vehicle system:
– Press button “01 - Engine electronics” on display.
The display shows the identification of the engine control unit.
Select diagnostic function:
– Click the “011 - Measured values” button on the display.
– In the selection list, select “Positioner for high pressure turbo‐
charger, actual raw voltage” and switch until measured value
is displayed.
. Volkswagen AG
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– Connect hand vacuum pump - VAS 6213- to vacuumVunit.
olks
wa not
y gu
db ara
– Observing the displayed measured value, set aorivoltage
se of nte
760 mV by causing a vacuum of max. 0.65 bar.
au
th eo
ra
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un
pt
Caution
an
d
itte
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ab
During the following procedure for adjusting the control rod,
pe
ility
keep the partial vacuum and thus the voltage of 760 mV con‐
ot
wit
, is n
stant.
h re
hole
spec
es, in part or in w
t to the co
– Slowly screw the locknut-B- of the control rod downwards by
hand. Adjusting lever is resting on the lower »stop«.
rrectness of i
– Counterhold locknut-B- and screw securing nut-A- onto the
control rod towards the adjusting lever. Tighten slightly with a
l purpos
ring spanner 10x12 - T10423- .

– Allow partial vacuum to escape from the vacuum unit.
nform
ercia
– Observe displayed measured value; value at normal pressure

m
a
com
t
should be set at 3,000 … 3,400 mV.
ion in
r
te o
– Fit 10 AF socket - T10422 A- , hold locknut -B- and tighten

thi
s
iva
securing nut -A-.

do
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Caution
yi Co
Cop py
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Cause a partial vacuum of 0.65 ± 0.05 bar to act on the vacuum py by
co Vo
unit in order to ensure that the adjusting lever rests against the
by lksw
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Prote
»stop«. When this is done, the voltage should automatically be
AG.
set to 760 mV.
Voltage OK.
1. Turbocharger 237
– Press locking plate by hand onto the control rod and, if possi‐
ble, turn 90° in the -direction of the arrow-.
– Seal connection between control rod and securing nut with
sealing paint from the spare-parts kit.
Voltage not OK.
– Counterhold locknut -B-, undo securing nut -A- of the control

rod and correct the voltage by turning the locknut -B-.
– Hold locknut -B-, turn securing nut -A- in opposing direction
and tighten it with 10 AF socket - T10422 A- .
– Press locking plate by hand onto the control rod and, if possi‐
ble, turn 90° in the -direction of the arrow-.
– Seal connection between control rod and securing nut with
sealing paint from the spare-parts kit.
Continuation
– Remove sealing cap from turbocharger. agen
AG. Volkswagen AG d
oes
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– Complete the engine. ed byV gu
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– Start motor and delete event memory ⇒ Vehicle diagnostic
aut
h eo
ra
tester . ss c
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pt
– Check setting as follows: an
d
itte
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Select diagnostic function:
rm
ab
pe
ility
– Click the “006 - Basic setting” button on the display.

ot
wit
, is n
h re
– Select “Adaptation of turbocharger” from selection list.

hole
spec
es, in part or in w
– Click the “Measured values” button on the bottom right on the

t to the co
display.
– Select “Positioner for high pressure turbocharger, actual raw
voltage” from selection list.
rrectness of i
– Click the “Start” button on the bottom right on the display.

l purpos
– Observe value in lower part of screen. It must fluctuate be‐

nform
tween 650 to 850 mV and 3,000 to 3,400 mV (vacuum unit is

ercia
moved to both end stops alternately).

m
a
com
tio
If voltage values OK:

n in
r
te o
thi
– End basic setting procedure.

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2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 239
⇒ “2.2 Removing and installing charge air cooler”, page 240
⇒ “2.3 Assembly overview - charge-air hose connections”,
page 242
⇒ “2.4 Removing and installing charge pressure sender”,
page 242
⇒ “2.5 Checking charge air system for leaks”, page 243
⇒ “6 Vacuum system”, page 284
2.1 Assembly overview - charge air system
Vol
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1 - Air intake hose s au
or
ac
s
❑ »Hot« side, top.
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2 - Left air pipe

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❑ »Hot« side.
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3 - Sleeve
is n
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ole,
4 - 9 Nm
spec
5 - Grommet
t to the co
6 - Air intake hose
rrectne
❑ »Hot« side, bottom.
ss
7 - Gasket
o
cial p
f in
8 - Charge air cooler
form
mer
atio
m
⇒ page 240
o
n
c
i
or
n thi
9 - Gasket
te
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10 - 5 Nm um
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11 - Mounting
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13 - Air intake hose Prote
cted AG.
agen
❑ »Cold« side, bottom.

14 - Air intake hose
❑ »Cold« side, top.
15 - Air pipe (right side)
❑ »Cold« side.
16 - Bolt
❑ 5 Nm
17 - Charge air pressure sender - G31- / intake air temperature sender - G42-
18 - O-ring
❑ Renew.
2. Charge air system 239

Installing air hoses with screw-type clips
Note
To securely attach the intake hoses on their unions, spray the

worm screws of the used hose clips with penetrating spray before
installing.
Specified torques
Hose clips -1- 5.5 Nm
♦ -a- = 13 mm wide
Hose clips -2- 3 Nm

♦ -b- = 9 mm wide
2.2 Removing and installing charge air cool‐

er
Removing
– Removing radiator ⇒ page 222 .
wage
– Remove front bumper cover ⇒ General yV
o body repairs, exterior; s not g
lks e
Rep. gr. 63 ; Front bumper; Removing
ise
d b and installing front ua
ran
bumper . thor tee
or
au ac
s
– Unbolt air ducts on left and right from charge air cooler.
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
Risk of injury caused by refrigerant.

hole
spec
es, in part or in w
♦ The air conditioner refrigerant circuit must not be opened.

t to the co
rrectness of i
Caution
l purpos
Danger of damage to condenser, refrigerant lines and hoses.

nform
ercia
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

m
a
com
tion in
– Unscrew bolt from refrigerant line retaining clamp next to lon‐

r
te o
thi
gitudinal member.
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Prote AG.

– Unscrew bolts -1- for charge air cooler and -2- for condenser.
– Swing charge air cooler backwards slightly.
– Unscrew bolt from lower right refrigerant line bracket on

charge air cooler.
– Swing condenser forwards into opening on lock carrier.
– Detach charge air cooler upwards out of lock carrier and re‐
move diagonally downwards.
Installing
⇒ “2.1 Assembly overview - charge air system”, page 239 .
Note

agen
AG. Volkswagen AG d
to original equipment ⇒ Electronic Parts CatalogueV(ETKA) .
w o es n
olks ot g
y ua
db ran
rise tee
– Install condenser ⇒ Heating, air conditioninguthsystem;
o
Rep. gr. or
87 ; Refrigerant circuit; Removing and installing
ss a
condenser . ac
ce
le
un
– Installing intake hoses with screw-type clips ⇒ page 242 . pt

an
d
itte
– Install front bumper cover ⇒ General body repairs, exterior; y li

erm
ab
Rep. gr. 63 ; Front bumper; Removing and installing front ility
ot p
bumper .
wit
is n
h re
ole,
– Installing radiator ⇒ page 222 .

spec
t to the co
Specified torques
rrectne
Charge air cooler 8 Nm

Hose clips ⇒ “2.1 Assembly overview - charge air system”,
ss
page 239
o
cial p
f in
Fitting the charge-air system hose connections ⇒ “2.3 Assembly overview - charge-air hose connec‐
form
mer
tions”, page 242

atio
om
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Prote AG.

2.3 Assembly overview - charge-air hose

connections
Note
♦ Check all air hoses and pipes to make sure they are firmly
seated and not leaking before carrying out tests or repairs.
♦ In order to securely attach the intake hoses on their unions,
spray the worm screws of the used hose clips with penetrating
spray before installing.
Caution
The screw-type clips -A- on the charge air lines must always
be tightened as specified ⇒ page 242 . If the torque is too low
or too high, the charge air hose may slip off the corrugated pipe
connection or the charge air pipe when the vehicle is used.
Installing air hoses with screw-type clips

Specified torques
♦ -a- = 13 mm wide
AG. Volkswagen AG d
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Hose clips -2- d by 3 Nm
V gu
ara
♦ -b- = 9 mm wide orise nte
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2.4 Removing and installing charge pres‐

pe
ility
ot
sure sender
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
– Remove noise insulation-1- ⇒ General body repairs, exterior;

sulation .
rrectness of i
l purpos
nform
mercia
a
com
tion in
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te o
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s
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AG. Volkswagen AG d
agen oes
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d by ara
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aut CC 2012
, Golf Cabriolet 2012 ➤ ra ➤
c
s
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unscrew bolts -1-, pull charge pressure sender - G31- / intake
ility
ot p
air temperature sender - G42- out of the air pipe.
wit
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
• Specified torque
⇒ “2.1 Assembly overview - charge air system”, page 239 .
rrectness of i
l purpos
Note
nf
ercia
Renew O-ring.
orm
m
atio
m

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tion .
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Installing
o
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Note cted agen
Prote AG.
Renew O-ring.
Specified torque
Charge air pressure sender - G31- / intake air temper‐ 5 Nm
ature sender - G42-
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687- with adapter - V.A.G
1687/12-
Procedure

AG. Volkswagen AG d
agen oes
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CC 2012 ➤ , Golf Cabriolet 2012 ➤ by
Vol not
gu
d ara
4-cylinder diesel engine (2.0 l engine, oriscommon rail, generation II) - Edition 09.2013
e nte
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aut ra
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– Pull off crankcase breather hose -1- from
ss
cylinder head cover;
ce
le
press release buttons for this.
un
pt
an
d
itte
y li
erm
ab
-1-.
ility
ot p
wit
is n
h re
ole,
– Release hose clips -3- and remove air hose from air filter
spec
housing. urposes, in part or in wh
t to the co
off from turbocharger.
rrectness
o
cial p
f inform
– Undo hose clip -1- and remove the pulsation damper -2-.
mer
atio
om
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– Insert adapter - 1687/12- into intake hose -1- and secure with
a clip.
Prepare charge air system tester - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- completely and close

valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

– Connect charge air system tester - V.A.G 1687- to adapter -

1687/12- as shown.
AG. Volkswagen AG d
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spec
es, in part or in w
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– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- .
AG. Volkswagen AG d
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Note ed b ara
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If there is water in inspection glass, drain via drain
ss a screw -6-. c
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nl
pt
du
– Open valve -3-.
an
itte
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ab
– Adjust pressure to 0.5 bar with pressure control valve -2-.
ility
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Caution
hole
spec
es, in part or in w
The pressure must not exceed 0.5 bar! If the pressure is too
t to the co
high this can cause damage to the engine.
rrectness of i
– Open valve -4- and wait until test circuit is full. If necessary,
l purpos
regulate the pressure to 0.5 bar.

– Check charge-air system for leaks by:
nform
ercia
♦ listening
m
at
om
i
♦ feeling
on
c
in t
or
♦ using standard leak detecting spray
his
ate
do
riv
♦ Ultrasonic tester - V.A.G 1842-

p
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for
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Cop py
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♦ Slight leaks on the intake side of turbocharger are permissible, cted agen
Prote AG.
as the intake hoses are not designed for high-pressure.
♦ A small amount of air escapes through the valves and enters
the engine. Therefore a holding pressure test is not possible.
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions .
♦ If a leak has been located, observe notes for charge air system
when carrying out any repair work.
♦ Depressurise test circuit by detaching coupling from adapter -
1687/10- before removing adapter.
Reassembly
Installation is carried out in the reverse order. While doing so, note
the following:
Note
♦ Renew the seal and O-ring.

– Installing inlet connection and pulsation damper ⇒ page 226 .


23 – Mixturey Vopreparation - dinjection

AG. gen AG Volkswa
agen oes
lksw not
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1 Injection system
tho e or
au ac
ss
ce
le
⇒ “2 Safety instructions”, page 3

un
pt
an
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erm
ab
ility
⇒ “1.1 Schematic overview - fuel system”, page 247
ot p
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is n
⇒ “1.2 Filling, bleeding fuel system”, page 249
h re
ole,
spec
⇒ “1.3 Checking fuel system for leaks”, page 250
t to the co
1.1 Schematic overview - fuel system
rrectne
WARNING
ss
♦ Read rules for cleanliness and the instructions for working
o
cial p
f
on the fuel system ⇒ page 6 .
inform
mer
♦ Always follow these rules for cleanliness and instructions
atio
before starting work and while working on the fuel system.
om
n
c
i
or
n
♦ If components of the fuel system between the tank and the
thi
te
high-pressure fuel pump are removed or renewed, the fuel
sd
iva
o
r
system must be filled to be bled ⇒ page 249 . (It is im‐

p
cum
r
fo
portant not to allow the high-pressure pump to run while en

ng
t.
yi
still empty.)
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1. Injection system 247

1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6- .
❑ ⇒ Rep. gr. 20 ; Fuel AG. Volkswagen AG d
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2 - Fuel filter rised
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❑ With pre-heating valve. aut ra
c
ss
❑ ⇒ Rep. gr. 20 ; Fuel fil‐
ce
le
un
ter
pt
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3 - Supplementary fuel pump -
rm
ab
pe
V393- or fuel pump 2 - V277-
ility
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❑ Does not apply to CC
h re
hole
❑ Does not apply to Golf
spec
Cabriolet with 0.5 bar
es, in part or in w
t to the co
system
❑ ⇒ Fuel supply system –
diesel engines; Rep. gr.
rrectness of i
20 ; Fuel pump; Remov‐
ing and installing fuel
l purpos
pump
nform
ercia
Note
m
a
com
t
The component designation for the
ion in
inline electronic fuel pump was
r
te o
thi
changed from “supplementary
s
iva
pump V393” to “fuel pump 2 V277”
do
r
rp
c
in a software revision. This is the
um
fo
en
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same component.
n
t.
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4 - Filter strainer rig ht
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by lksw
5 - Fuel temperature sender - cted agen
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G81-
❑ After renewing, a first
fuel filling must be performed (never allow the pump to run while it is still empty) ⇒ page 249 .
7 - Fuel metering valve - N290-
❑ Must not be removed.
8 - Fuel pressure regulating valve - N276-
❑ Removing and installing ⇒ page 274 .
9 - High-pressure accumulator (fuel rail)
10 - Fuel pressure sender - G247-
11 - Non-return valve
❑ The non-return valve may only be renewed as a unit together with the fuel return lines.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
12 - Injectors
❑ Injector, cylinder 1 - N30-
248 Rep. gr.23 - Mixture preparation - injection

1.2 Filling, bleeding fuel system
Caution
Risk of irreparable damage to high-pressure pump if allowed

to run dry.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty.
Note
♦ When installing the high-pressure pump, it is essential to en‐

sure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.
♦ There must be sufficient fuel in the tank.
– Switch ignition on.

– Connect vehicle diagnostic tester and perform the guided
function “Bleeding fuel system” orge“Filling/bleeding fuel
AG. Volkswagen AG sys‐
a n does
tem” depending on software Voversion.
lksw not
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Note ss
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un
pt
The fuel pumps will now be activated for a total of 3 minutes.

an
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– Start engine.
ility
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– After filling fuel system, leave the engine running at moderate

h re
ole,
speed for a few minutes and then switch it off again.

spec
– Checking fuel system for leaks ⇒ page 250

t to the co
– Read out event memory and, if necessary, delete the event

memory entry ⇒ Vehicle diagnostic tester .
rrectne
– Road-test the vehicle for more than 20 km. Accelerate with full
throttle at least once. Then check high-pressure part of fuel
ss
system again for leakage.

o
cial p
f inform
mer
Note
atio
om
n
c
i
or
If there is any air left in the fuel system, the engine may switch to
thi
te
the backup mode ('emergency running' mode) during the road

sd
iva
test. Switch off engine and clear event memory. Then continue
pr
cum
r
fo
road test.
en
ng
t.
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Cop py
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– Read event memory again.
rig
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Prote AG.
Note
road test.
– Read event memory.
1. Injection system 249

1.3 Checking fuel system for leaks

– Allow engine to idle for a few minutes but do not accelerate.
Then switch off engine again. Fuel system will bleed itself au‐
tomatically.
– Check fuel system for leaks.
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
– Road-test the vehicle. Accelerate with full throttle at least
once, then check the high-pressure section again for leaks.
Note
road test.
lkswage es n
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ility
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spec
es, in part or in w
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rrectness of i
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nf
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orm
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or c
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Prote AG.

2 Injectors/high-pressure accumulator
(rail)
⇒ “2.1 Assembly overview - injectors”, page 251
⇒ “2.2 Adapting correction values for injectors”, page 253
⇒ “2.3 Testing jammed-open injectors”, page 254
. Volkswage n AG n AG d
wage oes
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olks injectors”, page 255 not
gu
b ara
ed
⇒ “2.5 Removing andho installing high-pressure
ris accumulator (rail)”,nte
eo
page 260 s aut ra
c
s
⇒ “2.6 Removing and installing high-pressure lines”, page 263
ce
le
un
pt
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2.1 Assembly overview - injectors
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ab
ility
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1 - Seal
h re
ole,
spec
❑ In cylinder head cover.
t to the co
⇒ page 103
2 - Copper washer
rrectne
❑ Renew.
s
3 - O-ring
s o
cial p
f
❑ Renew.
inform
mer
4 - Injector
atio
m
❑ When removing and in‐

o
n
c
stalling, always renew

or
n thi
e
the following compo‐

t
sd
va
nents and seals/O-

i
o
pr
cum
r
rings: “copper seal”, “O-

fo
en
ng
ring for injector bore”,

t.
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op
“O-ring for injector re‐
C py
ht. rig
turn connection”. rig ht
py by
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lksw
❑ The following compo‐
by
cted agen
Prote
nents and seals/O-rings
AG.
must always be re‐

newed when an injector
is renewed: “clamping
piece”, “copper seal”,
“O-ring for injector shaft”
and “O-ring for injector
return connection”.
❑ Before re-using “high-
pressure line”, inspect
taper seats for damage
such as transverse
scores or corrosion; al‐
ways renew if damaged.
❑ If they are to be reinstal‐
led, the injectors, high-
pressure lines and
clamping pieces must
only ever be refitted on the same cylinder.
❑ Before installing, clean injector bore using cleaning set - VAS 6811-
5 - O-ring
❑ Renew.
2. Injectors/high-pressure accumulator (rail) 251


❑ To fuel tank.
❑ Must not be kinked, damaged or blocked.
❑ Do not dismantle.
❑ After exchanging, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
check fuel return lines for leaks.
❑ Renew.
8 - Clamping piece
❑ If they are to be reinstalled, the injectors and clamping pieces must only ever be refitted on the same
cylinder.
❑ When an injector is renewed, the clamping piece mustwabe genrenewed
AG. Volkswat the same
agen AG
does time.
olks not
❑ Installation position ⇒ page 253 . db
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ar
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ris tee
9 - High-pressure line, 28 Nm tho or
au ac
❑ Between high-pressure accumulator (fuel
s rail) and injectors.
s
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nl
pt
du
an
Note
itte
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erm
ab
ility
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♦ Observe cylinder specific mark‐
wit
ings when reusing high-pressure
, is n
h re
lines.
hole
spec
♦ The high-pressure lines may be
es, in part or in w
t to the co
re-used after the following
checks:
♦ Check taper seal of respective
rrectness of i
high-pressure line for deforma‐
l purpos
tion and cracks.

♦ The line hole must not be de‐
nf
ercia
formed, constricted or damaged.
orm
m
♦ Corroded lines should no longer
atio
m
be used.
o
n in
or c
thi
te
❑ Install so that component is not under tension. sd

iva
o
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rp
cu
10 - 22 Nm
o
m
f
en
ng
t.
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11 - High-pressure accumulator (fuel rail) ht. Cop py
rig
❑ Removing and installing ⇒ page 260 rig ht
py by
co Vo
by lksw
12 - Fuel return hose cted agen
Prote AG.
13 - Fuel pressure regulating valve - N276- , 80 Nm.

❑ Always renew after removing.
14 - O-ring
❑ Renew.
15 - High-pressure line, 28 Nm
❑ Between high-pressure pump and high-pressure accumulator (fuel rail).
Note

lines.
checks:


tion and cracks. wage
es n
lks ot g
Vo
♦ The line hole must not be de‐ ed by ua
ran
thoris tee
u or
a ac
♦ Corroded lines should nosslonger
be used.
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le
un
pt
an
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itte
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16 - 8 Nm
erm
ab
ility
ot p
❑
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is n
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17 - Fuel pressure sender - G247- , 100 Nm
ole,
spec
❑ Always renew after removing.
t to the co
18 - Grommet
rrectne
❑ In cylinder head cover.
ss o
cial p
f inform
Clamping piece installation position
mer
atio
m
• One clamping piece encompasses 2 injectors each.

o
n
c
i
or
n
• Thick part -arrow- of clamping piece points downwards.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.2 Adapting correction values for injectors

The function “Adaptation of correction values for injectors” serves
to correct the injection rates for each cylinder of a common rail
system individually across the entire ignition map range.

The 7-digit correction values -1- (details in illustration are only an

example) are marked separately on each injector. The marked
values may consist of letters and/or numbers.
Top view of injector
1 - Checksum
2 - DATA Matrix Code
3 - Part number
After renewing an injector, the correction value must be written
into the engine control unit.
After the engine control unit has been replaced, the “correction
values for the injectors” must be transferred to the new engine
control unit.
The adaption procedure is described in Guided Fault Finding.
gen AG
. Volkswagen AG
a does
lksw not
Also check that the “injector delivery calibration values” db
yV
o
are cor‐ gu
ara
rectly entered for all the other injectors. Do not oattempt
ir se to re-enter nte
these values if the correct values are already au stored in the engine
th eo
ra
control unit. ss c
ce
e
nl
pt
Select correct vehicle in Guided fault finding.
du
an
itte
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– Press “GoTo” button.
erm
ab
ility
ot p
– Press “Function/component selection”.
wit
, is n
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– Select “drive (Rep. Gr. 01; 10 - 39)”.
hole
spec
es, in part or in w
– Select respective engine code.
t to the co
– “01 - Self-diagnosis compatible systems”
– Select “01 - Diesel direct injection and glow plug system
rrectness of i
EDC 17”.
l purpos
– Select “01 - Functions”.

– Select “01 - Read/adapt correction values for injectors”
nform
mercia
at
2.3 Testing jammed-open injectors
om
ion
c
in t
or
his
ate
WARNING
do
priv
cum
for
en
g

n
t.
yi Co
op
on the fuel system ⇒ page 6 . C py
t. rig
gh ht
yri by
♦ Always follow these rules for cleanliness and instructions cop Vo
by lksw
before starting work and while working on the fuel system. cted agen
Prote AG.


swage es n
♦ Make an -adapter- from a return line. byV
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Erase fault memory entry with vehicle diagnostic tester.
ss o
– Clean all connections (e.g. with commercial cleaning solution)
cial p
f in
before removing.
form
mer
atio
om
n
Note
c
i
or
n thi
te
sd
va
♦ Make sure all parts are clean; no dirt must be allowed to enter
i
o
pr
cum
r
the fuel system.

fo
en
ng
t.
yi Co
♦ Check one cylinder after the other. t. Cop py
rig
gh ht
pyri by
Vo
– Dry all cleaned parts.
co lksw
by
cted agen
Prote AG.
Start with cylinder 1.
– Pull return line connections off at injectors. To do this, press
bows -1- and -2- down and simultaneously pull release pin
upwards -arrow-.
– Connect clean, blow-out adapter to injector to be tested.
– Use hand-operated vacuum pump - VAS 6213- to generate

vacuum of approx. -500 mbar.
If injector is OK, pressure remains constant for 30 s.
If injectors are defective, the pressure will drop back to 0 bar within
2 ... 3 s.
Repeat check is necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew defective injectors ⇒ page 255
2.4 Removing and installing injectors


♦ Puller - T10055-
AG. Volkswagen AG d
agen oes
olksw not
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
♦ Assembly sleeve - T10377-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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♦ Puller -T10415- t. Cop py
rig
gh ht
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Removing p by
co Vo
by lksw
cted agen
Prote AG.
WARNING

Caution
♦ Identify the cylinder numbers on the injectors. Injectors

must only be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ The open connections must be sealed with a suitable cap.

– Pull return line connections off at injectors. To do this, press

bows -1- and -2- down and simultaneously pull release pin n AG. Volkswagen AG do
upwards -arrow-. wage es n
olks o t gu
yV
db ara
rise nte
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au ra
c
ss
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect electrical connectors -arrows- at injectors.
Caution
rrectness of i
l purpos
When releasing high-pressure line, counterhold high-pressure

connection at injector unit using open-ended spanner. Leaks
occur if high-pressure connection is released.
nform
mercia
a
com
tio
– Unscrew union nuts of relevant high-pressure line -1 to 4- and
n in
r
remove corresponding high-pressure line.

te o
thi
s
iva
do
– Unscrew securing bolt -1- of the clamping piece of the injector
r
rp
cum
which is to be removed.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Fit puller - T10055- with puller -T10415- and pull injector out
upwards using tapping movements.
Note
Pull injector out using rotary movements in order not to damage

sealing lip.
AG. Volkswagen AG d
agen oes
lksw not
– Place the removed injectors on a cleanbycloth. Vo gu
ara
d
ise nte
Important instructions for installing injectors
uthor eo
a ra
s c
• Clean empty injector bores and s sealing surfaces in cylinder
ce
le
head using cleaning set - VAS 6811- before fitting injectors ⇒

un
pt
an
d
Instructions
itte
y li
erm
ab
• When removing and installing, always renew the following
ility
ot p
components and seals/O-rings: “copper seal”, “O-ring for in‐
wit
is n
jector bore”, “O-ring for injector return connection”.
h re
ole,
spec
• The following components and seals/O-rings must always be
renewed when an injector is renewed: “clamping piece”, “cop‐
t to the co
per seal”, “O-ring for injector shaft” and “O-ring for injector
return connection”.
rrectne
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
ss o
cial p
f in
Note
form
mer
atio
♦ Observe cylinder specific markings when reusing high-pres‐
om
n
sure lines.
c
i
or
n thi
te
sd
♦ The high-pressure lines may be re-used after the following
iva
o
r
checks:
p
cum
r
fo
en
ng
♦ Check taper seat of respective high-pressure line for defor‐

t.
yi Co
op
mation and cracks.
C py
t. rig
gh ht
yri by
♦ The line hole must not be deformed, constricted or damaged. cop Vo
by lksw
cted agen
Prote
♦ Corroded lines should no longer be used.
AG.
If a used injector is being re-installed:

– Spray tip of injector with a rust removal spray. Wait approx.
5 minutes and wipe off soot and oil particles with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.

en AG. Volksw(2.0
age nl engine,
AG common rail, generation II) - Edition 09.2013
ag does
ksw not
Vol g
– Renew seal for injector
edb
y bore using assembly sleeve - uaran
T10377- . ho
ris tee
aut or
a
– To avoid damaging
ss the O-ring, carefully slide the new, oiled c
ce
O-ring onto the fuel return connection. e
nl
pt
du
an
itte
– Install injectors.
y li
erm
ab
ility
– Tighten union nuts of high-pressure lines hand-tight. Check
ot p
wit
they are seated without stress.
, is n
h re
hole
spec
⇒ “2.1 Assembly overview - injectors”, page 251 .
es, in part or in w
t to the co
– Press return line connections carefully over the seals and onto
the injectors (first check seal for damage). The catch should
engage audibly. Then press release pin down carefully.
rrectness of i
After one or more injectors has been replaced, the correction val‐
l purpos
ues for the new injectors must be entered into the engine control
unit ⇒ Vehicle diagnostic tester.
nform
ercia
Also check all the other injectors to find out whether the correct
m
correction values have been stored in the engine control unit. Do
at
om
io
not attempt to re-enter these values if the correct values are al‐
n
c
in t
r
ready stored in the engine control unit.

o
his
ate
do
riv
– Bleeding fuel system ⇒ page 249 .

p
cum
for
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
The high-pressure connections must not be opened for bleeding.
by c lksw
cted agen
Prote AG.
– Allow engine to run at idling speed for a few minutes and then
turn it off.
– Switch off ignition.
– Check the complete fuel system and return line connections
(4 connections) for leaks ⇒ page 250 .
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
Note
The return lines can only be renewed together with the non-return
valve as one unit.
– Road-test vehicle extensively. Accelerate with full throttle at

least once, and then check high-pressure section again for
leaks.
Note
test. Switch off engine and clear event memory ⇒ Vehicle diag‐
nostic tester . Continue road test.

2.5 Removing and installing high-pressure

accumulator (rail)
Caution


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Removing
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WARNING
ole,
spec

on the fuel system ⇒ page 6 . t to the co
rrectne

ss o

cial p
f inform
– Disconnect electrical connector -arrow- on fuel pressure reg‐

mer
atio
ulating valve - N276- .

om
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– Disconnect electrical connector -B- on fuel pressure sender -

G247- .
– Pull vacuum hose -A- from cylinder head cover.
– Remove fuel return hose from high-pressure accumulator

(rail); release hose clip -arrow- to do so.
– Open retaining clips -arrows- of wiring harness.

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ility
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es, in part or in w
– Pull off electrical connectors at the glow plugs.

t to the co
rrectness of i
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nform
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at
om
ion
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ate
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– Release and unplug connector -arrow-at the injectors.

– Thread electric cables out of the cable guide.
– Unclip the vacuum hose at the hose guide.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
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ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
– Unscrew bolt -2- and union nuts -1 and 3-, and remove high-
ot
wit
pressure line.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Unscrew bolts -2-, lay coolant return line aside.
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– Unscrew bolts -arrows-, lay coolant return line aside.

– Remove line guide from high-pressure accumulator (rail) and
place to one side.

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nte Cabriolet 2012 ➤
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ac 09.2013
ss
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– Undo union nuts of 4 high-pressure lines -1-.
un
pt
an
d
itte
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– Place high-pressure lines on a clean cloth.
rm
ab
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ility
ot
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
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– Remove high-pressure accumulator (rail) by unscrewing the
nform
ercia
two bolts -arrows-.

m
a
com
ti
– Seal open connections with engine bung set - VAS 6122- .
on in
r
te o
thi
Installing
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iva
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– Install high-pressure lines (free of tension) ⇒ page 263 .
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Note
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Prote AG.
♦ Observe cylinder specific markings when reusing high-pres‐

sure lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seat of respective high-pressure line for defor‐
mation and cracks.
♦ The line hole must not be deformed, constricted or damaged.
♦ Corroded lines should no longer be used.
Specified torques
Injectors 8 Nm +180°
High-pressure accumulator (fuel rail) 22 Nm
2.6 Removing and installing high-pressure

lines

♦ Socket - T40055-
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Removing horis nte
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WARNING
ce
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un
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an
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itte
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rm
ab

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ility
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, is n

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hole
spec
es, in part or in w
t to the co

rrectness of i
Caution
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♦ Mark allocation of high-pressure lines to cylinder. High-

pressure lines must only be reconnected to same cylinder.
nform
ercia
♦ Observe rules for cleanliness when working on the injec‐

m
tion system.
com
tion in
r
♦ The open connections must be sealed with a suitable cap.

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– Disconnect electrical connectors -arrows- at injectors.
Caution
When releasing high-pressure line, counterhold high-pressure

connection at injector unit using open-ended spanner. Leaks
occur if high-pressure connection is released.
– Unscrew union nuts of relevant high-pressure line -1 to 4- and

remove corresponding high-pressure line.
– Place high-pressure lines on clean surface and cover with lint-
free cotton cloth.
Installing
Caution
Undo high pressure accumulator (rail) and clamping pieces so

that the injection lines will fit easily free of tension. If necessary,
shift high pressure accumulator (rail) slightly and turn relevant
injector slightly if required. The lines must never be bent or
tensioned. Tension would otherwise cause the respective line
to break in the long-term.
Note agen
AG. Volkswagen AG d
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This section describes how to installrisnew
ed high-pressure lines. If nte
high-pressure lines which were already
ut
ho
fitted are to be used eo
ra
again, the points listed under ⇒ssItem 9 (page 252) (9) must be
a c
checked again. Apart from that the procedure is identical.
ce
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nl
pt
du
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itte
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– If you have not yet done so, loosen the securing bolts of the
erm
ab
high-pressure accumulator (rail) so that it can be moved.

ility
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– If not done, undo the securing bolts of the clamping pieces and
h re
make sure the injectors can rotate.

hole
spec
es, in part or in w
– Remove the new high-pressure line from the packaging. Re‐

t to the co
move the sealing plugs and position the line between the high-
pressure pump and the high pressure accumulator (rail).
rrectness of i
– Initially hand-tighten high-pressure line union nuts “fully” on

high-pressure pump without tools.
l purpos
– Ensure that line is correctly seated.

nf
ercia
– If necessary, proceed in the same way with other injection

or
lines.
m
m
atio
om
n in
c
– Tighten components with the socket wrench - T40055- ac‐

or
thi
e
cording to the specified tightening sequence ⇒ page 266 .

t
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WARNING
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The securing clamp for the high-pressure line between the
gh ht
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high-pressure pump and high-pressure accumulator (fuel rail)
o Vo
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cted
must always be installed in the correct position. Otherwise fa‐
agen
Prote AG.
tigue failures or stress ruptures may occur in the high-pressure
line.

Installation position for the high-pressure line securing clamp

– Tighten securing clamp to 8 Nm.
– Carefully press the return line connections onto the injector
(check seal for damage). You should hear them click into
place. Then carefully press the release pin downwards.
– Filling fuel system ⇒ page 249 .
Caution

AG. Volkswagen AG d
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Observe tightening sequence and specified d by Vtorques gu
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Tightening sequence aut
h Specified
ra torque
ss c
1. Securing bolt for clamping piece 8 Nm + turn 180° further
ce
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nl
pt
du
2. High-pressure line between high-pressure accumulator (rail) and 28 Nm
an
itte
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injector
erm
ab
ility
ot p
3. High-pressure fuel line fixtures between high-pressure pump and 28 Nm
wit
high-pressure accumulator (rail)
, is n
h re
hole
4. Securing bolts of high-pressure accumulator (fuel rail) 22 Nm
spec
es, in part or in w
5. Securing clamp for high-pressure line between high-pressure ac‐ 8 Nm
t to the co
cumulator (rail) and high-pressure pump
rrectness of i
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3 High-pressure pump
⇒ “3.1 Assembly overview - high-pressure pump”, page 267
⇒ “3.2 Removing and installing high-pressure pump”, page 268
3.1 Assembly overview - high-pressure pump
1 - Bracket for ancillaries

⇒ page 50
❑ Renew.
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❑ Use counterholdl - rised
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T10051- to loosen and ut
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tighten. ss a c
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❑ To remove, use puller -

un
pt
an
T40064- .
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4 - High-pressure pump tooth‐
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5 - 20 Nm
ole,
spec
❑ Renew.
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6 - 95 Nm
rrectne
❑ Renew.
ss o
cial p
❑ With fuel metering valve
f in
- N290- (do not open).
form
mer
❑ After renewing, initial
atio
m
fuel filling must be car‐

o
n
c
i
or
n
ried out (never allow
thi
e
pump to run dry)

t
sd
iva
⇒ page 249 .
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⇒ page 268 t. Cop py
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9 - Fuel supply hose yri
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10 - Fuel return hose
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Prote AG.
11 - High-pressure lines, 28
Nm
❑ Between high-pressure pump and high-pressure accumulator (fuel rail).
❑ Do not interchange.
Note

lines.
checks:
tion and cracks.
3. High-pressure pump 267

♦ The line hole must not be de‐

♦ Corroded lines should no longer
be used.
❑ Install so that component is not under tension.
3.2 Removing and installing high-pressure pump

equipment required
♦ Puller - T40064- with
T40064/1
1331-
AG. Volkswagen AG d
agen oes
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nl
pt
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ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
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nform
mercia
at
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ion
c
in t
or
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ate
do
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cum
for
en
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Prote AG.

Removing
Caution
♦ Observe safety instructions ⇒ page 3 .

♦ Observe rules for cleanliness and the instructions for
working on the fuel system ⇒ page 6 .
to run dry.
be allowed to run while still empty. Initial fuel filling
⇒ page 249 .
– Remove toothed belt from camshaft and high pressure pump

⇒ page 110 .
– Unscrew bolts -2-, remove toothed belt sprocket from high-
pressure pump.
AG. Volkswagen AG d
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ab
ility
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spec
– Unscrew nut -1- at hub of high-pressure pump. To do this,

es, in part or in w
t to the co
counterhold with counterhold - T10051- .

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Position puller - T40064- with thrust piece - T40064/1- and pin

f
en
g
- T40064/2- as shown and pull hub off high-pressure pump.

n
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Use an 24 AF open-ended spanner to hold. C py
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CC 2012 ➤ , Golf Cabriolet 2012 ➤ n AG. Volkswagen AG do
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4-cylinder diesel engine (2.0 l engine,y Vcommon
olks rail, generation II) s- nEdition
ot g 09.2013
b ua
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ris tee
– Unscrew bolts -2-, lay coolant return thline aside.
o
or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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fo
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t.
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Prote AG.
– Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure
line.
– Release and pull off electrical connectors -1- and -3-.

– Remove fuel supply hose -2- and return hose -4-.

AG. Volkswagen AG d
Vehicles with high-pressure
lksw
pump
agen support oes
not
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– Unscrew nuts -1-
ris
edand screw
b
-2- from the support -A-. arant
ee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew bolts -arrows- for high-pressure pump.
l purpos
– Carefully remove high-pressure pump.

Installing
nf
ercia
or
m
m
atio
om
n in
or c
thi
te
sd
iva
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– Gently put on high pressure pump and tighten the screws gh ht
yri by
-arrow-. cop Vo
by lksw
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Prote AG.
⇒ “3.1 Assembly overview - high-pressure pump”, page 267 .
Vehicles with high-pressure pump support
Prescribed torques and tightening sequence .

St Component Specified torque
ag
e
1 Centre hex studs for support 15 Nm
2 Tighten nuts -1- and screw-2- hand tight
• It must still be possible to move the support

St Component Specified torque

ag
e
3 Bolt -2- 23 Nm
4 Nuts -1- 23 Nm

– Install high-pressure lines ⇒ page 263 .
lkswage es n
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Caution byV ua
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ir se tee
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or
au ac
ss
to run dry.
ce
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nl
pt
du
an
itte
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erm
ab
be allowed to run while still empty. Initial fuel filling
ility
ot p
⇒ page 249 .
wit
, is n
h re
hole
spec
es, in part or in w
Specified torques
t to the co
High pressure pump on the auxili‐ Bolts M8 x 28 20 Nm +45°
rrectness of i
ary equipment carrier
l purpos
Bolts M8 x 90 20 Nm 180°
Hub on the high pressure pump 95 Nm nform
ercia
Toothed-belt pulley on the hub 20 Nm

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om
ion
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or
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ate
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Prote AG.

4 Senders and sensors

⇒ “4.1 Checking fuel pressure regulating valve”, page 273
⇒ “4.2 Removing and installing fuel pressure regulating valve”,
page 274
⇒ “4.3 Removing and installing fuel pressure sender”, page 276
⇒ “4.4 Removing and installing air mass meter”, page 279
⇒ “4.5 Removing and installing differential pressure sensor”, page
280
4.1 Checking fuel pressure regulating valve

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♦ Measuring container, fuel-resistant
rrectne
WARNING
♦ Follow the rules of cleanliness for all work on the fuel sys‐
ss o
tem ⇒ page 6 .
cial p
f inform
mer

atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
– Remove fuel return hose from high-pressure accumulator

en
ng
t.
(rail); release hose clip -arrow- to do so.
yi Co
Cop py
t. rig
– Seal open fuel return hose using a bung from engine bung set gh ht
yri by
- VAS 6122- . cop Vo
by lksw
cted agen
Prote AG.
4. Senders and sensors 273

– Connect auxiliary hose -2- to return connection of high-pres‐

sure accumulator (rail) -2-.
– Hold auxiliary hose in measuring container -4- to measure re‐
turn quantity.
– Start engine and allow the engine to run 30 seconds at idling
speed.
• Specified amount in 30 seconds: 90 to 110 ml.
If the specification is not attained, the fuel pressure regulating
valve - N276- is defective.
lkswage es n
o ot g
byV ua
4.2 Removing and installing fuel pressure
d ran
ir se tee
tho
regulating valve u or
a ac
ss
ce
le
Fuel pressure regulating valve - N276- -2- is located in high-pres‐

un
pt
an
d
sure accumulator (rail). It maintains constant pressure in high-

itte
y li
rm
pressure accumulator (rail) and injection lines (high-pressure fuel
ab
pe
ility
circuit).
ot
wit
, is n
If pressure is too high in the fuel high pressure circuit, the regu‐
h re
hole
lating valve will open. Thus, a small amount of fuel from the high
spec
pressure accumulator (rail) will run back to the fuel tank via the
es, in part or in w
t to the co
return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
rrectness of i
pressure section of the system from the low-pressure section.
l purpos
Note
nform
mercia
Fuel pressure regulating valve - N276- must be renewed each

a
com
tio
time after removing.

n in
r
te o
thi
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n
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Removing
WARNING

Location ⇒ Item 13 (page 252)

– Removing high-pressure accumulator (rail) ⇒ page 260 .
– Before removal, clean thread area around fuel pressure reg‐
ulating valve - N276- using commercial cold cleaning solution
etc. (no dirt must enter the bore in the high-pressure accumu‐
lator).
lkswage es n
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byV ua
Note ir se
d ran
tee
tho
u or
a ac
Clean carefully; cleaning solvent must not enter the electrical
ss
ce
connector.
le
un
pt
an
d
itte
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erm
– Dry fuel pressure regulating valve - N276- .
ab
ility
ot p
– Undo union nut while holding the hexagonal flats on the hous‐
wit
is n
ing. Then unscrew and remove by hand.
h re
ole,
spec
– Extract the dirt from hole of high pressure accumulator (rail)
(threads and sealing surface). Do not use tools or other in‐
t to the co
struments for this purpose.
– Seal open hole of high-pressure accumulator (rail) using a
rrectne
bung from engine bung set - VAS 6122- .
Installing
ss o
cial p
f
inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
♦ The fuel pressure regulating valve - N276- has a deformable

t
sd
iva
sealing lip and no separate seal; it can therefore be used only

pr
cum
r
fo
once.
en
ng
t.
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op
♦ Make sure that sealing surfaces (deformable sealing lip) and C py
t. rig
threads on new fuel pressure regulating valve - N276- are un‐
gh ht
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damaged.
co Vo
by lksw
cted agen
Prote AG.
♦ Check sealing surface at hole of high-pressure accumulator
(rail).
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
ulating valve - N276- must be moistened with diesel.
– Tighten union nut by hand.

– Align new fuel pressure regulating valve so that connecting
line is free of tension after connector is attached.
– Hold regulating valve in this position with an open-ended
spanner on the housing hexagon or use a wrench (e.g. water
pump wrench).
– Use a suitable torque wrench with an open-end insert (30 mm)
to tighten union nut.

– Install high-pressure accumulator (rail) ⇒ page 260 .

– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
– Check fuel system for leaks.
– Read event memory ⇒ Vehicle diagnostic tester .
– Then road-test the vehicle. Accelerate with full throttle at least
– Read event memory again.
Specified torque
Fuel pressure regulating valve - N276- 80 Nm
4.3 Removing and installing fuel pressure

sender
Fuel pressure sender - G247- -Item B- is located in high-pressure
accumulator (rail). It measures the current fuel pressure in the
high-pressure system and transmits a voltage signal to the engine
control unit - J623- .
AG. Volkswagen AG d
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aut ra
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ot

wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
thi
s
iva
do
r
Removing
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cum
fo
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t.
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op
WARNING C py
ht. rig
rig ht
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♦ Observe rules for cleanliness and the instructions for by c lksw
cted agen
Prote AG.


AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
d
ri4-cylinder
se diesel engine (2.0 l engine, common
nte rail, generation II) - Edition 09.2013
ho eo
aut ra
ss c
– Before removal, clean thread area around the fuel pressure
ce
e
sender using e.g. a commercially available cold cleaning sol‐
nl
pt
du
an
vent. No dirt must enter the bore.
itte
y li
erm
ab
– Open cable strip -arrow- Pull plug from the glow plugs.
ility
ot p
wit
, is n
– Lay cable harness to one side.
h re
hole
spec
es, in part or in w
Note
t to the co
Clean carefully; cleaning solvent must not enter the electrical
connector.
rrectness of i
l purpos
– Dry fuel pressure sender - G247- .

– Release and pull off electrical connector -B- from the fuel
nf
ercia
o
pressure sender - G247- .
rm
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or c
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

– Unscrew fuel pressure sender - G247- .

– Extract the dirt from hole of high pressure accumulator (rail)
(threads and sealing surface). Do not use tools or other in‐
struments for this purpose.
– Seal open hole of high-pressure accumulator (rail) using a
bung from engine bung set - VAS 6122- .
Installing
Note
♦ Fuel pressure sender - G247- has a deformable sealing lip,

not a seal, for sealing purposes.
♦ Make sure that the sealing surfaces (deformable sealing lip)
and threads on fuel pressure sender - G247- are not damaged.
Reusing fuel pressure sender - G247- if possible if it has been
tested OK.
♦ Check sealing surface at hole of high-pressure accumulator
(rail).
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
ulating valve - N276- must be moistened with diesel.
– Tighten fuel pressure sender - G247- by hand.

– Tighten fuel pressure sender - G247- .
– After installing fuel pressure sender - G247- , allow engine to
run at moderate speed for a few minutes in order to bleed the
fuel system.
Note
wage es n
The high-pressure connectionsbymust Volks
“not” be opened for bleed‐ ot g
ua
ing; fuel system bleeds itselfir seautomatically.
d ran
tee
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u or
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– Read out event memory and, if necessary, delete it ⇒ Vehicle
ss
ce
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diagnostic tester .
nl
pt
du
an
itte

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erm
ab
ility
– Carefully check entire fuel system for leaks.

ot p
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, is n
– Renew the affected component if leakage still occurs after

h re
hole
tightening to the correct torque.

spec
es, in part or in w
– Then road-test the vehicle. Accelerate with full throttle at least

t to the co

rrectness of i
Note
l purpos
nf
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rm
m
road test.
atio
om
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– After road test, read out event memory again.

thi
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278
Prote AG.
Rep. gr.23 - Mixture preparation - injection
Specified torque
Fuel pressure sender - G247- 100 Nm
4.4 Removing and installing air mass meter

Removing
– Carefully pull air mass meter - G70- out of guide on air filter
AG. Volkswagen AG d
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housing. Volksw
oes
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Installing rise nte
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Install in reverse order. While doing so, note
ss the following: c
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⇒ “7.1 Assembly overview - air filter housing”, page 288 .
itte
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erm
ab
To ensure the proper function of the air mass meter - G70- it is
ility
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important to adhere to the following work sequences.
wit
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spec
Note
es, in part or in w
t to the co
♦ If the air filter element is very dirty or wet, particles of dirt or
water may reach the air mass meter and falsify the measured
rrectness of i
air mass value. This would lead to loss of power, since a
smaller injection quantity is calculated.
l purpos
♦ Use original air filter.
nf
ercia
♦ Always renew seal if damaged (infiltrating air).
orm
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atio
♦ Use a silicone-free lubricant to install the air hose and seal.
om
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– Check for salt residue, dirt and leaves in air mass meter and p by
o Vo
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air hose (clean air side).
lksw
cted agen
Prote AG.
– Check intake channel for contamination as far as air filter el‐
ement. If contamination is found, remove salt residues, dirt
and leaves from top and bottom part of air filter housing by
flushing it out or using a vacuum cleaner if necessary.
– Install air filter housing ⇒ page 289 .

CC 2012 ➤ , Golf Cabriolet AG.2012
Volksw➤
agen AG
agen does
4-cylinder dieselVoengine
lksw (2.0 l engine, common not rail, generation II) - Edition 09.2013
y gu
db ara
ise nte
4.5 Removing and installing differential
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tho eo
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pressure sensor
ss c
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⇒ “4.5.1 Removing and installing pressure differential sender

itte
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G505 ”, page 280
erm
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ility
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4.5.1 Removing and installing pressure differ‐
wit
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ential sender - G505-
ole,
spec
t to the co
Note
rrectne
Pressure differential sender - G505- determines charge status of
particulate filter. It can be connected via two lines before and after
the particulate filter, or with just one line before the particulate
ss
filter. In this case, the pressure transducer measures the ambient
o
cial p
f i
pressure with an open line and calculates the pressure difference.
nform
mer
atio
m
Fitting location ⇒ page 307

o
n
c
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or
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Removing
thi
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– Unscrew bolt -3-, pull pressure differential sender - G505- from
bracket -arrow-.
– Remove clips from both hoses.
– Pull hoses carefully and straight from unions (unions break off
pressure sensor very easily).
Installing
Note
♦ Before installing, blow out control lines of pressure differential

sender - G505- to particulate filter with compressed air to‐
wards particulate filter (blocked or iced up due to condensa‐
tion).
♦ Make sure that hoses are securely fitted and seal properly.
Volkswa
♦ If pressure hoses have been detached
swa from particulate filter,
gen AG
. gen AG
does
tighten ⇒ page 307 . by
Volk not
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Adaptation must be performed aut
after renewing pressure differen‐ ra
c
s
tial sender - G505- and/or sparticulate filter. (The procedure is also
ce
le
described under Guided Functions).

un
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Select correct vehicle in Guided fault finding.
rm
ab
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– Press “GoTo” button.
ot
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– Press “Function/component selection”.
hole
spec
– Select “drive (Rep. Gr. 01; 10 - 39)”.
es, in part or in w
t to the co
– Select respective engine code.
– “01 - Self-diagnosis compatible systems”
rrectness of i
– Select “01 - Diesel direct injection and glow plug system

l purpos
EDC 17”.
– Select “01 - Functions”.
nform
ercia
– Select “01 - Reset programmed values of the differential pres‐

m
sure sender of the Diesel Particle Filter (DPF)”.

com
tion in
r
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Specified torques
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Bracket on supplementary fuel pump 8 Nm
Co
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Differential pressure sender - G505- on the bracket gh
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CC 2012 ➤ , Golf Cabriolet 2012 ➤ AG. Volkswagen AG d
agenII) - Edition 09.2013
4-cylinder diesel engine (2.0 l engine, common rail, generation oes
olksw not
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5 Lambda probe ss
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c
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un
⇒ “5.1 Removing and installing Lambda probe”, page 282
pt
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d
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5.1 Removing and installing Lambda probe
rm
ab
pe
ility
ot
wit
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h re
hole
♦ Lambda probe open ring spanner set - 3337-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
do
r
Fitting location ⇒ page 307

rp
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Removing
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– Disconnect electrical connector -arrow- for Lambda probe -
by lksw
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G39- .
AG.
– Expose cable harness.
– Unscrew Lambda probe - G39- -3-, using tool from Lambda

probe open ring spanner set - 3337- .
Installing
Note
♦ New Lambda probes are coated with an assembly paste. The

paste must not get into the slots on the probe body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the probe body. High-temperature paste ⇒ Electronic
Parts Catalogue (ETKA)
♦ When installing, the Lambda probe's electrical wiring connec‐
tion must always be re-attached in the same locations to
prevent the Lambda probe cable from coming into contact with
the exhaust pipe.

waggeneration
en AG. V II) - Edition
olkswagen AG
doe 09.2013
ks s no
Vol t gu
by ara
Specified torque ris
ed
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Component ss
a
Specified torque c
ce
le
Lambda probe 50 Nm
un
pt
an
d
♦ Grease only the threads with high-temperature paste - G 052
itte
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erm
112 A3- ; high-temperature paste - G 052 112 A3- must not get
ab
ility
into the slots of probe body.
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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or
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5. Lambda probe 283

6 Vacuum system
⇒ “6.1 Vacuum hose schematic diagram”, page 284
⇒ “6.2 Testing vacuum system”, page 285
6.1 Vacuum hose schematic diagram
Caution
Do not kink, twist or crush the vacuum lines when routing. This
may cause breakdowns.
1 - Vacuum unit
❑ On turbocharger.
❑ With position sender for
charge pressure posi‐
tioner - G581- .
2 - Charge pressure control
solenoid valve - N75-
3 - Silencer
4 - Air filter
5 - To brake booster
6 - Connection piece wage
es n
lks
❑ On vacuum pump d byV
o ot g
ua
ran
ir se tee
7 - Non-return valve utho
or
a ac
❑ Note installation posi‐ ss
ce
le
tion.
un
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cooler changeover valve -
ility
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N345-
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9 - Cylinder head cover
ole,
spec
10 - Vacuum unit
❑ For changeover for ex‐ t to the co
haust gas recirculation
cooler.
rrectness o
cial p
f inform
mer
atio
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n
c
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6.2 Testing vacuum system

⇒ “6.2.1 Checking supply line, vacuum reservoir and non-return
valve”, page 285
⇒ “6.2.2 Checking control line to turbocharger”, page 286
6.2.1 Checking supply line, vacuum reservoir

and non-return valve
AG. Volkswagen AG d
agen oes
lksw not
Caution d by V o gu
ara
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th
Do not kink, stwist
au or crush the vacuum lines when routing. Thisor ac
may cause sbreakdowns.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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atio
om
n in
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thi
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– Pull off vacuum hose -II-on the charge-pressure control sole‐

r
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noid valve - N75- .

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– Seal hose ends with suitable plugs. C py
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Note Prote AG.
Do not use screws or threaded bolts.
6. Vacuum system 285

– Pull off vacuum hose -arrow- from the vacuum pump connec‐
tion.
– Connect hand vacuum pump - VAS 6213- to the hose
n AG. Volkswhich
wagen AG
has been removed and generate a vacuum wage
olks of 0.6 bar.
does
no t gu
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by ara
– Watch the gauge of the hand vacuum
ris
ed pump for about 30 sec. nte
tho eo
• Vacuum must not drop. s au ra
c
s
ce
If vacuum drops: e
nl
pt
du
an
itte
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– Find damage or leaking connections in the hose and replace
erm
ab
the piece of hose.
ility
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If pressure does not drop:
h re
hole
– Pull hose off the hand vacuum pump - VAS 6213- .
spec
es, in part or in w
t to the co
– Remove one of the plugs from the hose end.
– If the non-return valve functions properly, a clear hiss is audi‐
ble when vacuum in vacuum reservoir is released.
rrectness of i
If no hiss is audible:
l purpos
– Replace check valve.
nf
ercia
If a hiss is audible:
orm
m
atio
– Reconnect vacuum hoses.
om
n in
or c
– Checking control line to turbocharger ⇒ page 286 .
thi
te
sd
iva
o
r
rp
cu
6.2.2 Checking control line to turbocharger
o
m
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. rig
Caution
ht ht
rig by
copy Vo
by lksw
cted
Do not kink, twist or crush the vacuum lines when routing. This
agen
Prote AG.
may cause breakdowns.


– Detach hose from middle connection of charge-pressure con‐

trol solenoid valve - N75- -arrow in I- and from turbocharger
vacuum unit -arrow in II-.
– Seal hose opening with suitable plug.
Note
Do not use screws or threaded bolts.
– Connect hand vacuum pump - VAS 6213- to the other end of

the hose and generate a vacuum of 0.6 bar.
– Watch the gauge of the hand vacuum pump for about 30 sec.
• Vacuum must not drop.
If vacuum drops:
– Renew vacuum hose.
AG. Volkswagen AG d
If pressure does not drop: lksw
agen oes
not
Vo gu
by
– Reconnect vacuum hoses. rised ara
nte
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aut ra
ss c
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
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thi
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6. Vacuum system 287

7 Air filter
⇒ “7.1 Assembly overview - air filter housing”, page 288
⇒ “7.2 Removing and installing air filter housing”, page 289
7.1 Assembly overview - air filter housing
1 - Hose connection
2 - Air intake hose
❑ To turbocharger.
❑ Check for soiling and
leaves.
3 - 1.5 Nm
❑ Qty. 2
4 - Air mass meter - G70-
❑ Removing and installing AG. Volkswagen AG d
⇒ page 279 lksw
agen oes
n o ot g
yV ua
5 - O-ring ris
ed
b ran
tee
o
❑ Renew. au
th or
ac
ss
❑ Install with silicone-free
ce
le
un
lubricant.
pt
an
d
itte
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6 - 1.5 Nm
erm
ab
ility
ot p
❑ For upper part of air fil‐

wit
ter.
is n
h re
ole,
7 - 8 Nm
spec
❑ For lower part of air filter

t to the co
8 - Sleeve
9 - Washer
rrectne
10 - Air filter upper part

ss
❑ Remove dirt, leaves and

o
cial p
salt residues.
inform
mer
11 - Air filter element

atio
m
❑ Observe change inter‐

o
n
c
i
or
vals ⇒ Maintenance ;
thi
e
Booklet 808
t
sd
iva
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cum
12 - Air filter lower part

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fo
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ng
t.
yi
❑ Remove dirt, leaves and salt residues.
Co
Cop py
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❑ For cold countries, an air filter lower part is installed with a hose for hot air intake.
rig
gh ht
pyri by
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❑ Country-specific version: With snow screen.
co lksw
by
cted agen
Prote AG.
13 - Connection for water drain hose
❑ Clean.
14 - Water drain hose
❑ Clean.
15 - Flutter valve
❑ Cleaning and reinstalling.
16 - Intake air duct
❑ To lock carrier.
❑ Remove dirt, leaves and salt residues.

17 - Spring-type clips
18 - Connecting hose
❑ To turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Installing air hoses with riscrew-type
se
d clips nte
tho eo
au ra
ss c
Note
ce
e
nl
pt
du
an
itte
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In order to securely attach the intake hoses on their unions, spray
erm
ab
the worm screws of the used hose clips with penetrating spray
ility
ot p
before installing.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Specified torques
l purpos

nform
ercia
♦ -a- = 13 mm wide
m
at
om
ion
Hose clips -2- 3 Nm
c
in t
or
♦ -b- = 9 mm wide
his
ate
do
priv
cum
for
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t.
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op
7.2 Removing and installing air filter hous‐
C py
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Prote AG.
Removing
– Pull cover off air duct by releasing retaining clips at sides
-arrows-.
7. Air filter 289

– Unclip lower air duct -2- by releasing retaining clips on left and
right -arrow A-.
– Unclip air duct at mountings -3-. In order to do so, swing air
duct downwards and slightly to rear.
– Detach air pipe -1- from lower air duct -arrow B-.
– Disconnect electrical connector -1- at air mass meter - G70-

and pull hose -2- off.
– Remove air hose; loosen hose clip -4- for this.
– Unscrew bolt -3- and remove air filter housing.
Installing
⇒ “7.1 Assembly overview - air filter housing”, page 288 .
Note AG. Volkswagen AG d

agen oes
olksw not
♦ Hose connections and air intake pipes/hoses
byV must be free of gu
ara
ed
oil and grease when installing. tho ris nte
eo
au ra
♦ Use a silicone-free lubricant to
s install the air hose.
s c
ce
le
un
pt

an
d
itte

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rm
ab
pe
ility
ot
wit
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– Disconnect water drain hose -arrow- from air filter lower part
h re
and clean dirt and leaves from connection and hose.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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rp
cum
fo
en
ng
t.
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Cop py
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rig ht
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by lksw
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Prote AG.

8 Intake manifold
⇒ “8.1 Assembly overview - intake manifold”, page 291
⇒ “8.2 Removing and installing intake manifold”, page 292
⇒ “8.3 Removing and installing throttle valve module”,
page 295
8.1 Assembly overview - intake manifold
1 - Guide tube
❑ For oil dipstick.
2 - Seal
❑ Renew.
3 - Gasket
❑ Renew.
4 - 8 Nm
6 - 9 Nm
❑
7 - Intake manifold
⇒ page 292
8 - Bracket
❑ For exhaust gas recircu‐
lation cooler change‐
over valve - N345- . agen
AG. Volkswagen AG d
oes
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9 - 9 Nm ed by gu
ara
ris nte
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10 - Exhaust gas recirculation auth eo
ra
cooler changeover valve - ss c
N345-
ce
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11 - Gasket
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❑ Renew.
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12 - 20 Nm
h re
hole
spec
13 - Connecting pipe
es, in part or in w
❑ To exhaust gas recircu‐

t to the co
lation cooler.
14 - Clamp, 5 Nm
rrectness of i
❑ Renew.
l purpos
15 - Connection
❑ For exhaust gas recirculation.
nform
ercia
16 - 8 Nm
m
at
om
io
17 - Seal
n
c
in t
or
❑ Renew.
his
ate
do
priv
18 - Throttle valve module - J338-

um
for
en
g
❑ With throttle valve potentiometer - G69- .

n
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❑ Removing and installing ⇒ page 295 t. C rig
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8. Intake manifold 291

19 - 8 Nm
20 - 9 Nm
21 - Clip
8.2 Removing and installing intake manifold

♦ Socket Torx T 30 - T10405-
Removing
WARNING

working on the fuel system ⇒ pageo6lks.wagen AG
en AG. V wag does
olks not
byV gu
ara
ed nte
– Remove ris
enginethocover panel ⇒ page 41 . eo
au ra
– Remove noise insulation ⇒ General body repairs, exterior; ss c
ce
e

nl
pt
du
sulation .
an
itte
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erm
ab
– Remove air intake hose. To do this, loosen hose clip -2-.

ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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by lksw
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Prote AG.


– Loosen hose clip -2- on throttle valve module - J338- , pull air
pipe off and leave in installation position.
– Disconnect electrical connectors at glow plugs ⇒ page 355 .
lkswage es n
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d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
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rm
ab
pe
ility
ot
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– Remove exhaust gas recirculation cooler changeover valve -
h re
hole
N345- -left arrow- from bracket and lay aside.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Unscrew bolts -2-, lay coolant return line aside.

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. Volkswagen AG
does gen AG
– Unscrew bolt -2- and Vunion
olks nuts -1, 3-; remove high-pressure
wa not
line. ed by gu
ara
is nte
or
– Removing high-pressure
au
th accumulator (rail) ⇒ page 260 . eo
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect electrical connector -2- at throttle valve module -
rrectness of i
J338- .
l purpos
– Remove bolt -1- for dipstick guide tube.

– If support is fitted between throttle valve module and crank‐
nform
ercia
case, remove it.

m
a
com
tion in
r
te o
thi
s
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Cop py
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– Open and remove clip -1-. pyri by
Vo
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cted agen
Prote AG.
– Unscrew bolts -arrows- for intake manifold diagonally from

outside to inside using socket T30 - T10405- .
– Carefully remove intake manifold.
Installing
Note
Renew seals and gaskets.
– Tighten bolts from inside out in diagonal sequence.

– Install air pipe.
– Install high-pressure accumulator (rail) ⇒ page 260 .
tion .
– Filling with coolant ⇒ page 189

Specified torques
Intake manifold 8 Nm
Oil dipstick 10 Nm
Connecting pipe 20 Nm
High-pressure accumulator (fuel rail) ⇒ “2.5 Removing and installing high-pressure accu‐
mulator (rail)”, page 260
8.3 Removing and installing throttle valve

module
Removing
– Remove noise insulation: ⇒ General body repairs, exterior;
sulation .
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- G31- and remove air pipe.

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– Remove bolt -1- for dipstick guide tube.
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Throttle valve module - J338- to intake manifold 10 Nm
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Oil dipstick 10 Nm
Connecting pipe 20 Nm
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9 Engine control unit

⇒ “9.1 Removing and installing engine control unit”, page
wa297
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If engine control unit is to be replaced, connect ⇒ Vehicle diag‐
nostic tester and carry out “Renew control unit” guided function.
Removing
rrectne
ss
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
o
cial p
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inform
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– Push locking devices of connectors in direction of -arrow- and

pull off connectors.
Installing
9. Engine control unit 297

– Fit connectors to engine control unit and slide locking devices

onto stop in -direction of arrow-.
– Place engine control unit into retaining frameAand push retain‐

n G. Volkswagen AG do
ing frame upwards in direction of -arrow-.
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overview – plenum chamber au bulkhead . ra
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9.1.2 Removing and installing engine control
unit - J623- with protective housing
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If the engine control unit is to be replaced, connect ⇒ Vehicle di‐
l purpos
agnostic tester and carry out “Renew control unit” guided function.
Removing
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– Unscrew shear-head bolts -arrow- using a pair of pliers.
– Insert screwdriver between both locking plates -arrow-.

– Carefully press screwdriver in -direction of arrow- and bend
retaining bar -1- upwards at the same time.
– Bend retaining bar -1- in direction of -arrow- until it can be

pulled off connector.
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9. Engine control unit
– Fit connectors to engine control unit and slide locking devices

onto stop in direction of -arrow-.
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– Place engine control unit into retaining frame and push retain‐
ing frame upwards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs,

screen wiper system; Removing and installing wiper arms .

26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 301
⇒ “1.2 Aligning exhaust system free of stress”, page 304
⇒ “1.3 Installation position of clamp”, page 305
1.1 Assembly overview - silencers

⇒ “1.1.1 Assembly overview - silencer, Golf Cabrio”, page 301
⇒ “1.1.2 Assembly overview - silencer, CC”, page 302
⇒ “1.1.3 Assembly overview - silencer, CC with SCR system”,
page 304 wage
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1.1.1 Assembly overview - silencer, Golf Cab‐ ris
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Mounting position and specified torque of the clamping sleeve

un
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⇒ page 305
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1 - 25 Nm
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2 - Retaining ring
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3 - Rear silencer
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4 - Rear mounting
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5 - 25 Nm
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6 - Tunnel cross-piece
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1. Exhaust pipes, silencers 301

Detaching rear silencer

– Cut silencer at right angles at the mark -Arrow 2- on the rear
silencer.
– Insert the clamp between the marks -Arrow 1- and -Arrow 3-.
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1.1.2 Assembly overview - silencer, CC
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♦ Mounting position and specified torque of the clamping sleeve
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⇒ page 305
es, in part or in w
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♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen clamping sleeve and align si‐
rrectness of i
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
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loaded.
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302 Rep. gr.26 - Exhaust system

1 - Clamp
❑ Before tightening, align
cold exhaust system
free of tension
⇒ page 304
❑ Tighten bolted connec‐
tions evenly.
⇒ page 305 .
2 - Rubber mounting
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1.1.3 Assembly overview - silencer, CC with SCR system
1 - From reducing catalytic

converter
2 - Clamp wage
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❑ Before tightening, align d byV ua
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⇒ page 304 ss
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4 - 25 Nm
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5 - Exhaust pipe
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❑ Before tightening, align
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⇒ page 304
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8 - Rear silencer
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1.2 Aligning exhaust system free of stress

• Engine must be cold.
– Loosen threaded connections -3- and -4- of front clamping
sleeve -1-.
– Align front clamp -1- to marking -A- on front exhaust pipe -2-
(-arrow- points forwards).
• Dimension -a- = 5 mm
• The bolts must be on the right and the ends of the bolts must
not protrude beyond the lower edge of the clamp.

– Push rear silencer forwards into clamp until dimension -a-

6.6 mm is attained between mountings for body and rear
silencer. -Arrow- points in direction of travel.
– Align rear silencer horizontally.
– Tighten clamp bolts in this position and to specified torque
⇒ page 305 .
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Specified torque and mounting dimensions of clamping sleeve.
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Clamp -A- with 2 individual clips.
Specified torque: 25 Nm.
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Installation dimensions -a- 5 mm (only for front clamp)
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Clamp -B- with continuous clip.
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Specified torque: 35 Nm.
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Installation dimensions -a- 6.6 mm (only for front clamp)
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1 - Clamp
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2 - Front exhaust pipe
a - Installation dimension
A - Marking
Installation position of front clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces right.

Installation position of rear clamp

– Install clamp so that end of bolt -arrow- does not extend be‐
yond lower edge of clamp.
• Threaded connection faces to rear. AG. Volkswagen AG d
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AG. Volkswagen AG d
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⇒ “2.1 Assembly overview – emission control”, page 307ut
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⇒ “2.2 Removing and installing particulate filter”, page 311 s
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⇒ “2.3 Removing and installing catalytic converter”, page 316
an
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2.1 Assembly overview – emission control
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⇒ “2.1.1 Assembly overview - front exhaust pipe with particulate
h re
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filter”, page 307
spec
⇒ “2.1.2 Assembly overview - front exhaust pipe with catalytic
t to the co
converter”, page 309
2.1.1 Assembly overview - front exhaust pipe
rrectne
with particulate filter
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Note
form
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♦ After working on the exhaust system, ensure that the system
om
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bodywork. If necessary, loosen clamping sleeve and align si‐
te
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maintained to the bodywork and the support rings are evenly
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♦ The decoupling element of the front exhaust pipe must be se‐
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cured with transportation lock - T10404- to stop overstretch‐ Prote AG.
ing.
Note
If the particle filter or differential pressure sender - G505- / pres‐

sure sensor 1 for exhaust - G450- is changed, the differential
pressure sender - G505- / pressure sensor 1 for exhaust - G450-
must be matched via the vehicle diagnostic tester ⇒ Vehicle
diagnostic tester.
2. Emission control 307

1 - 10 Nm
2 - Securing clip
3 - 7 Nm
4 - Differential pressure sender
- G505-
⇒ page 280
5 - Spring-type clip
6 - 8 Nm
7 - Bracket
❑ For pressure differential
sender - G505- .
8 - Shield
9 - 10 Nm
10 - Lambda probe - G39-
❑ 50 Nm
❑ Grease only the threads
with high-temperature
paste - G 052 112 A3- ;
high-temperature paste
- G 052 112 A3- must
not get into the slots of
probe body.
⇒ page 282
11 - Exhaust gas temperature n AG. Volkswagen AG do
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❑ Thread of sender is ss
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❑ Do not additionally oil or grease.

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13 - Clamp, 7 Nm
t to the co
14 - Particulate filter
❑ With oxidation catalytic converter and front exhaust pipe.
rrectness of i
❑ After renewing, the adaption of ash mass comparison must be set to zero with the vehicle diagnostic
l purpos
tester under “Guided functions”.

nform
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15 - 25 Nm
m
at
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16 - Mounting
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17 - Plug
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❑ Thread of sender is coated.

❑ Do not additionally oil or grease.
19 - 25 Nm
20 - Bracket
❑ Bolted to cylinder head.
21 - Bracket
❑ Bolted to diesel particulate filter.
22 - 25 Nm
23 - Bracket
24 - 25 Nm
25 - 25 Nm
26 - Control pipe
❑ From particulate filter
27 - Control pipe
❑ open end
❑ for measuring the ambient pressure
2.1.2 Assembly overview - front exhaust pipe

with catalytic converter
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♦ After working
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on the exhaust system, ensure that the system
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bodywork.
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♦ If necessary, loosen double and single clamps and align si‐

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evenly loaded .
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spec
♦ Removing and installing exhaust manifold with turbocharger

es, in part or in w
⇒ page 229 .
t to the co
♦ The flexible joint in the front exhaust pipe must not be bent
more than 10° - otherwise it can be damaged. Secure with
rrectness of i
transportation lock - T10404- .

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♦ Renew seals, gaskets and self-locking nuts.

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1 - Catalytic converter byV
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❑ Removing and installing horis tee
⇒ page 316 aut or
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3 - Clip
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❑ 7 Nm
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4 - 25 Nm
5 - 25 Nm
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6 - Bracket
❑ Bolted to crankcase
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7 - Bracket
inform
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8 - 25 Nm
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2.2 Removing and installing particulate filter

equipment required
♦ Lambda probe open ring
spanner set - 3337-
♦ Ratchet wrench 13 mm -
T10384-
♦ Tool set, 17 AF - T10395-
♦ Transport guard - T10404-
♦ Engine bung set - VAS
6122-
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– Separate connectors.
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♦ -1- for exhaust gas temperature sender 3 - G495-

♦ -3- for Lambda probe - G39-
– Open heat protection mat on the cables and thread the cable
out of the brackets.
– Remove Lambda probe - G39- -3- and exhaust gas tempera‐
ture sender 3 - G495- -1-.
– Loosen bolt -2- and remove clamp.

– Open clip of differential pressure line on particulate filter and
pull off differential pressure line.
– Undo and remove bolt -1- in upper bracket of particulate filter.

sulation .
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– Unscrew bolts (if any) -arrows- and remove heat shield for right
un
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drive shaft.
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Rep. gr.26 - Exhaust system
agen
Prote AG.
– Unplug connector for exhaust gas temperature sender 4 -

G648- .
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

from exhaust pipe downstream of particulate filter.
Caution

♦ The decoupling element must be secured with transpor‐
tation lock - T10404- -arrow-.
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– Undo clamping sleeve nuts -1- and push clamping sleeve to‐
wards rear.
rrectne
– Unscrew nuts -arrows- and remove tunnel cross-piece at front.
ss o
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Prote AG.

– Unscrew nuts -1- and -2- remove rear tunnel cross-piece

-arrows-.
lkswage es n
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ss
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un
pt
an
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erm
ab
ility
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ole,
– Remove bolts -arrows- of bracket.
spec
– Remove particulate filter bracket.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Unscrew securing nuts -1- above particulate filter bracket us‐

i
o
pr
cum
r
fo
ing ratchet wrench - T10384- ; unscrew nuts -2-.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew bolts -2- and -3- for pendulum support.

– Push engine/gearbox assembly with engine support device -

3300 A- forwards by measurement -a-.
– Remove particulate filter and turn it until exhaust pipe hangs
downwards.
– Unmount rear part of exhaust system at rubber mountings.
– Push rear part of exhaust system as far to the front and down‐
wards as possible.
– Unscrew nuts -arrows- from underbody cover.

– Unscrew clamping washers -2- and -3-.
– Guide heat shield -1- for transmission tunnel along exhaust
pipes and remove.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Remove particulate filter by turning it 180° around its own axis
wit
, is n
through the tunnel.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew securing nuts -1- above particulate filter bracket us‐

ing ratchet wrench - T10384- ; unscrew nuts -2-.
– Take particulate filter out downwards.
Installing
Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
Note rise nte
tho eo
au ra
♦ Renew seals, self-locking nuts
s and clip for particulate filter.
s c
ce
le
un
pt
♦ Fit cable ties in the same place when installing.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Observe sequence when installing particulate filter:
rrectne
1. Position particulate filter on turbocharger and secure clip
-1- loosely
ss o
2. Screw bolts -2 … 5- in loosely by hand
cial p
f in
• Particulate filter and retainer must be able to move
form
mer
atio
m
3. Tighten clip -1-

o
n
c
i
or
n
4. Tighten bolts -2- and -5-
thi
te
sd
a

iv
o
pr
cum
r
fo
– Installing exhaust temperature sender 4 - G648-

en
ng
t.
yi Co
⇒ page 337 . t. Cop py
rig
gh ht
– Aligning exhaust system free of stress ⇒ page 304 . pyri by
Vo
co lksw
by
cted agen
– Install Lambda probe - G39- together with lambda probe heat‐ Prote AG.
er - Z19- ⇒ page 282 .
– Install pressure differential sender - G505- ⇒ page 280 .
– After renewing particulate filter, carry out adaptation in “guided
functions” operating mode ⇒ Vehicle diagnostic tester.
Specified torques
Exhaust gas temperature send‐ ⇒ “4.2 Removing and installing parts of exhaust gas temperature regula‐
er tion”, page 338
Heat shield for drive shaft ⇒ Running gear, axels, steering; Rep. gr. 40 ; Drive shaft
Tunnel cross-piece ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody panel; Removing
and installing tunnel cross-piece
Subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe: Assembly over‐
view - subframe
Noise insulation ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly
overview - noise insulation .
2.3 Removing and installing catalytic con‐

verter

♦ Ratchet wrench 13 mm - T10384-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
♦ Transportation lock - T10404- rise
d ara
nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia

m
– Loosen bolt -2- and remove clamp.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew securing bolt -1- from upper bracket of catalytic con‐

verter.
Rep. gr. 50 .

– Unscrew bolts (if any) -arrows- and remove heat shield for right
. Volkswagen AG
drive shaft. swagen AG does
k not
Vol gu
d by ara
se nte
Caution thori eo
au ra
ss c
ce
e
nl
pt
du
an
♦ The decoupling element must be secured with transpor‐
itte
y li
tation lock - T10404- -arrow-.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Undo clamping sleeve nuts -1- and push clamping sleeve to‐ Cop py
wards rear.
t. rig
gh ht
pyri by
Vo
co
– Unscrew nuts -arrows- and remove tunnel cross-piece at front.
by lksw
cted agen
Prote AG.
– Unscrew nuts -1- and -2-, and remove rear tunnel cross-piece.

– Remove bolts -arrows- of bracket.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
– Unscrew securing nuts -1- above catalytic converter bracket
nl
pt
du
using ratchet wrench - T10384- ; unscrew nuts -2-.
an
itte
y li
erm
ab
– Remove catalytic converter bracket.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
– Unscrew bolts -2- and -3- for pendulum support.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Push engine/gearbox assembly with engine support device -

3300 A- forwards by measurement -a-.
– Remove particulate filter and turn it until exhaust pipe hangs
downwards.
– Detach rear part of exhaust system at rubber mountings.
– Push rear part of exhaust system as far to the front and down‐
wards as possible.

– Unscrew nuts -arrows- from underbody cover.

– Unscrew clamping washers -2- and -3-.
– Guide heat shield -1- for transmission tunnel along exhaust
pipes and remove.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Remove particulate filter by turning it 180° around its own axis
an
d
itte
y li
through the tunnel.
rm
ab
pe
ility
Installing
ot
wit
, is n
h re
• Specified torques for catalytic converter ⇒ page 309 .
hole
spec
• Specified torques for pendulum support ⇒ page 39
es, in part or in w
t to the co
• Specified torque for bolts for drive shaft heat shield -1- ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft ,
rrectness of i
• Specified torque for tunnel cross-pieces ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody panel; Removing and
l purpos
installing tunnel cross-piece

nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
♦ Renew seals, self-locking nuts and clip for catalytic converter.

do
r
rp
cum
fo
♦ Reinstall all cable ties in the same locations when installing.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Observe sequence when installing particulate filter: p by
co Vo
by lksw
cted agen
Prote
1. Locate catalytic converter filter on turbocharger and se‐
AG.
cure clip -1- loosely

2. Screw bolts -2 … 5- in loosely by hand
• It should still be possible to move catalytic converter
and bracket.
3. Tighten clip -1-


3 SCR system (selective catalytic re‐

duction)
⇒ “3.1 Assembly overview - tank for reducing agent”, page 321
⇒ “3.2 Emptying tank for reducing agent”, page 322
⇒ “3.3 Removing and installing reducing agent tank”, page 325
⇒ “3.4 Assembly overview - delivery module for reducing agent”,
page 327
⇒ “3.5 Removing and installing heater element (heater cup)”,
page 328
⇒ “3.6 Assembly overview - reducing agent delivery line”,
page 332
⇒ “3.7 Removing and installing reducing agent delivery line”, page
333
⇒ “3.8 Removing and installing injector for reducing agent”, page
335
3.1 Assembly overview - tank for reducing

agent
WARNING
♦ The reducing agent can irritate skin, eyes and respiratory

organs. gen AG
. Volkswagen AG
d a oes
lksw not
♦ After skin contact with this dagent,
by
Vo wash immediately with gu
ara
plenty of water. or
ise nte
eo
h
ut ra
♦ If necessary seek advice
ss
a from a doctor. c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. SCR system (selective catalytic reduction) 321

1 - Upper insulation
2 - Control unit for reducing
agent heater - J891-
3 - Delivery module
❑ With pump for reducing
agent - V437- .
⇒ page 328
4 - Tank for reducing agent
⇒ page 325
5 - Evaluation unit for reducing
agent tank - G698-
6 - Lower insulation
7 - Sheet metal tray
AG. Volkswagen AG d
agen
8 - 20 Nm olksw
oes
not
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ara
ed
ris nte
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
3.2 Emptying tank for reducing agent

m
atio
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
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m
f
en
ng
To keep the following description as short as possible the “NOx

t.
yi Co
op
reducing agent AUS 32” (AdBlue®) is just called a reducing agent.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING

organs.
plenty of water.
♦ If necessary seek advice from a doctor.

♦ Vacuum box - VAS 6557-

Note
Tank for reducing agent is emptied via filler neck.
Caution
Always ensure that no reducing agent contacts clothing or

bodywork.
If this occurs, wash out reducing agent using clear water and
a lint-free cotton cloth.
If the reducing agent has already crystallised, use warm water
and a sponge.
Reducing agent that has not been removed will crystallise and
damage the surface after some time.
For information on storage and disposal see ⇒ Service net →
Environment → Workshop disposal ! Request country specific
information concerning storage and disposal from importer.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Filler opening for tank for reducing agent is located in luggage
rise
d b ara
nte
compartment under floor covering. utho eo
ra
s a c
– Lift floor covering -1- and push back. s
ce
e
nl
pt
du
– Remove spare wheel -2-, if present. Unscrew wing nut -3- to
an
itte
y li
do so.
erm
ab
ility
ot p
– Remove foam piece, if present.
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Protect hands when removing cap from tank filler neck.
Risk of injury from sharp-edged body parts.
rrectness of i
l purpos
– Remove bung from tank filler neck -1-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Open tank cap -1- in luggage compartment.

Prepare vacuum box - VAS 6557- as follows:
– Close shut-off taps -A-, -B- and -C-.n AG. Volkswagen AG

age does
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y Vol gu
b ara
ed nte
oris eo
th
au ra
c
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Connect coupling -D- with connection to shut-off tap -A- and
pressurise compressed air hose with compressed air.
rrectness of i
– Open shut-off tap -A-.
l purpos
Now a vacuum is created in vacuum box - VAS 6557- .

– Close shut-off valve -A- as soon as the pressure gauge reg‐
nform
ercia
isters a pressure of 0.8 bar.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Disconnect coupling -D- from connection on shut-off tap -A- C py
t. rig
and interrupt compressed air supply at compressed air hose.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4-cylinder diesel engine (2.0 l engine, common rail, generation
. Volkswage
II) - Edition 09.2013
AG n AG d
agen oes
olksw not
– Guide end of hose -E- into filler neck as far as base of dreducing
by
V gu
ara
agent tank and open shut-off tap -B-. rise nte
tho eo
s au ra
c
s
ce
e
Note
nl
pt
du
an
itte
y li
erm
The reducing agent is then drawn from the tank and into the vac‐
ab
ility
uum box - VAS 6557- by the vacuum. The capacity of the vacuum
ot p
wit
box - VAS 6557- is 11 litres. This extracted volume is sufficient
, is n
h re
for removal of the reducing agent tank. If the reducing agent tank
hole
spec
holds a greater amount and the tank is to be emptied, then repeat
es, in part or in w
the process.
t to the co
– To drain vacuum box - VAS 6557- hold connection to shut-off
tap -C- over suitable container. Then open shut-off taps -A-
rrectness of i
and -C-.
l purpos
Caution
nf
ercia
or
Never reuse extracted reducing agent. For information on stor‐
m
m
atio
m
age and disposal see ⇒ Service net → Environment → Work‐

o
n in
c
shop disposal ! Request country specific information concern‐

or
thi
ing storage and disposal from importer.
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Flush out vacuum box - VAS 6557- carefully using water when
t.
yi Co
op
work sequence is complete. C py
t. rig
gh ht
pyri by
Vo
co
3.3 Removing and installing reducing agent
by lksw
cted agen
Prote AG.
tank
Note

WARNING

organs.
plenty of water.
Removing
– Emptying reducing agent tank ⇒ page 322 .

– Unscrew bolts -arrows- and remove cover -A- and bracket

-B-.
Caution

reducing agent by suitable means, e.g. plastic bag and cable
reducing agent.
– Unclip wiring connections -A- and -B- from retainer above rear olksw
axle and unplug electrical connector of delivery line -B-.
swa
gen AG
.V agen AG
does
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– First press securing clip for line connection together in direc‐
tion of -arrow 1- as shown, and pull off delivery line in direction
of -arrow 2- without tools and without »jerking«.
rrectne
Caution
ss o
cial p
f in
form
mer
atio
om
n
c
i
or
n
thi
e

t
sd
iva

pr
cum
r
fo

en
ng
t.
reducing agent.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove delivery module connectors -A- and -B- from their re‐
tainer above rear axle and unplug connectors.

– Place engine and gearbox jack - V.A.G 1383 A- under reduc‐

ing agent tank. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -arrows- and carefully lower reducing agent
tank.
Installing
rrectness of i
l purpos
Note
nform
ercia
Ensure all components are installed on the reducing agent tank,

m
the upper insulation fits exactly and that no lines are squashed.
at
om
ion
c
in t
or
– Carefully lift reducing agent tank using engine and gearbox
his
ate
jack - V.A.G 1383 A- until securing nuts can be fitted.
do
priv
cum
or
– Tighten securing nuts. Specified torque ⇒ Item 8 (page 322) .

f
en
ng
t.
yi Co
op
– Connect electric cables and delivery line and clip into brackets.
C py
t. rig
gh ht
pyri by
Vo
co
– Fit cover -A- and bracket -B-.
by lksw
cted agen
Prote AG.
– Fill reducing agent tank ⇒ Maintenance ; Booklet .
3.4 Assembly overview - delivery module for

reducing agent
WARNING

organs.
plenty of water.

1 - Wiring harness
2 - Delivery line
❑ For reducing agent.
❑ With heater for reducing
agent line - Z104- .
❑ Assembly overview
⇒ page 332 .
3 - 5 Nm
4 - Pump for reducing agent -
V437-
agent pump - Z103- .
❑ With pressure sender
for reducing agent me‐
tering system - G686- .
❑ With reversal valve for
reducing agent - N473- .
5 - Seal
❑ Renew. lkswage es n
o ot g
yV ua
6 - Gasket ir se
d b ran
tee
o
❑ Renew. auth or
ac
ss
7 - Locking ring, 80 Nm
ce
le
un
pt
an
❑ Remove and install us‐
d
itte
y li
ing wrench - T50014- .
erm
ab
ility
ot p
8 - Heater element (heater
wit
is n
cup)
h re
ole,
spec
agent tank - Z102- .
t to the co
❑ With reducing agent lev‐
el sender - G697- .
❑ With temperature send‐
rrectne
er for reducing agent -
G685- .
ss o
cial p
f inform
9 - Gasket
mer
atio
om
n
c
i
or
10 - Filter
thi
te
sd
va
11 - Seal
i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
12 - Cap C py
t. rig
gh ht
yri
❑ For filling. p by
co Vo
by lksw
❑ Accessible from luggage compartment.
cted agen
Prote AG.
3.5 Removing and installing heater element

(heater cup)
Note


lkswage es n
o ot g
byV ua
d ran
ho
ir se CC 2012 ➤te,eGolf Cabriolet 2012 ➤
t or
4-cylinder diesel
au engine (2.0 l engine, common rail, generation acII) - Edition 09.2013
ss
ce
le
un
pt
an
d
itte
WARNING
y li
erm
ab
ility
ot p
wit
is n
organs.
h re
ole,
spec
plenty of water.
t to the co
rrectne
ss
♦ Special wrench - T50014-
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Torque wrench - V.A.G 1332/-
Removing
– Remove reducing agent tank ⇒ page 325 .
– Remove upper insulation ⇒ Item 1 (page 322) .
Caution

reducing agent.

AG. Volkswagen AG d
agen oes
ksw
CC 2012 ➤ , Golf Cabriolet
by
Vol 2012 ➤ not
gu
d ara
4-cylinder dieselorengine
ise (2.0 l engine, common rail, generation nte II) - Edition 09.2013
h eo
aut ra
c
– Unplug connectorsss -arrows- at pump for reducing agent -
ce
le
V437- .
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– First press securing clip for line connection together in direc‐
o
cial p
f
tion of -arrow 1- as shown, and pull off delivery line in direction
inform
mer
atio
om
n
c
Caution
i
or
n thi
te
sd
va

i
o
pr
cum
r

fo
en
ng

t.
yi Co
Cop py
t.
rig
gh ht
yri by
reducing agent by suitable means, e.g. plastic bag and cable op Vo
by c lksw
ties. Electrical connections may be damaged due to the high cted agen
Prote AG.
reducing agent.
– Unplug connectors -2- and -3-, unscrew securing bolts -A- and
pull pump for reducing agent - V437- upwards.
– Cut cable ties -arrows- at locking ring and pull bleed line -1-
upwards.

– Place special wrench - T50014- onto locking ring as shown

and unscrew locking ring.
Caution AG. Volkswagen AG d

agen oes
olksw not
yV gu
When open, only tilt cover a max. of 30° this prevents
ised b
damage ara
nte
to electrical cables and suction probe of delivery
ut
hor
module. eo
ra
s a c
s
ce
e
nl
pt
du
– Open cover of delivery module, using removal wedge - 3409-
an
itte
y li
if necessary.
erm
ab
ility
ot p
– Carefully reach into cup of delivery module and release it from
wit
its locked position by turning anticlockwise.
, is n
h re
hole
– Remove delivery module upwards out of reducing agent tank.
spec
es, in part or in w
Installing
t to the co
– Place gasket ⇒ Item 9 (page 328) into opening in reducing
agent tank.
rrectness of i
l purpos
– Fit delivery module into reducing agent tank, noting markings

-A-. The markings -A- must align when inserting.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Carefully reach into cup of delivery module and engage it by
turning it clockwise. The marks -B- must align when engaged
correctly.
– Moisten sealing web of cover with water and carefully push

into gasket. The marks -1- must align.
– Put on locking ring and tighten until finger-tight.
Caution
Ensure sealing ring is not cross threaded on threads of reduc‐

ing agent tank. If the sealing ring does not sit properly, the
consequence will be leaks and considerable corrosion dam‐
age.

– Place special wrench - T50014- onto locking ring as shown

and tighten locking ring. Specified torque
⇒ Item 7 (page 328) .
– Wash off any leaks of reducing agent with water.
– Attach cable ties -arrows- to locking ring and pull bleed line
-1- upwards.
– Locate pump for reducing agent - V437- , attach connectors
-2- and -3-, and tighten securing bolts -A-. Specified torque
⇒ Item 3 (page 328) .
– Attach connectors -arrows- to pump for reducing agent - V437-

and connect delivery line -1-.
– Locate upper insulation ⇒ Item 1 (page 322) . n AG. Volkswagen AG do
lkswage es n
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yV
– Install reducing agent tank ⇒ page 325 . ir se
d b ua
ran
o tee
h
– Check for leaks ⇒ Vehicle diagnostic tester. aut or
ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
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spec
3.6 Assembly overview - reducing agent de‐
es, in part or in w
t to the co
livery line
rrectness of i
WARNING
l purpos

organs.
nform
ercia

m
at
plenty of water.
om
ion
c
in t
r

o
his
ate
do
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en
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Cop py
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by
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Prote AG.

1 - Quick release fastener

❑ For delivery line.
2 - Connector
❑ For heater for reducing
agent line - Z104- .
3 - Reducing agent delivery
line
⇒ page 333
4 - Injector for reducing agent -
N474-
⇒ page 335
5 - Gasket
❑ Renew.
6 - Clamp, 5 Nm n AG. Volkswagen AG do
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❑ Renew. yV
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ua
d b ran
7 - Reducing catalytic convert‐ ir se tee
tho
or
er au ac
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ce
le
8 - NOx sender 2 - G687-

un
pt
an
d
❑ 50 Nm
itte
y li
rm
ab
❑ With NOx sender 2 con‐
pe
ility
trol unit - J881- .
ot
wit
, is n
h re
❑ Remove right under‐
hole
body panel in order to
spec
remove and install.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
3.7 Removing and installing reducing agent

m
a
com
ti
delivery line
on in
r
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Note
um
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To keep the following description as short as possible the “NOx Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
WARNING

organs.
plenty of water.
– Remove left underbody panel.

– Remove heat shield above rear axle.

– Open delivery line clips, moving upper part in

-direction of arrow- as you do so.
Caution

reducing agent.
– Unclip connections from retainer above rear axle and unplug

electrical connector -B- of delivery line.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
ise nte
– First press securinguthor
clip for line connection together in direc‐ eo
ra
tion of -arrow 1-
ss aas shown, and pull off delivery line in direction c
ce
le
un
pt
an
d
itte
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Caution
rm
ab
pe
ility
ot
wit

, is n
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hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– First press securing clip for line connection on injector for re‐
ducing agent - N474- together in direction of -arrow 1- as
shown, and pull off delivery line in direction of -arrow 2- without
tools and without »jerking«.
– Carefully expose delivery line, pull out of remaining clips and
remove. wage
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Vol t gu
Installing ed by ara
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utho eo
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a
Caution ss c
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un
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an
The delivery line is pre-formed and is equipped with a heater
d
itte
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element over the complete length. Ensure the line is not kinked,
rm
ab
pe
twisted or stretched. Otherwise, the heater element and there‐
ility
ot
by the supply line will be damaged.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Guide delivery line carefully behind brake lines and wiring har‐
ness for electromechanical parking brake -arrows- above rear
l purpos
axle.
– Remove plug and connect delivery line to injector for reducing
nform
ercia
agent - N474- .
m
a
com
t
– Press delivery line into its clips from front to rear.
ion in
r
te o
– Close securing clips.
thi
s
iva
do
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– Remove plug.
rp
cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
– Connect wire -B- and delivery line -A- above rear axle. Secure
by lksw
cted agen
Prote
both in bracket mounted on body.
AG.
– Re-install heat shield above rear axle.

– Re-install underbody panel on driver side.
3.8 Removing and installing injector for re‐

ducing agent
Note


WARNING

organs.
plenty of water.
Removing
Caution

reducing agent. gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
– Unplug electrical connector ris
tho from injector for reducing agent - eo
N474- . ss
au ra
c
ce
le
– First press securing clip for line connection on injector for re‐
un
pt
an
d
ducing agent - N474- together in direction of -arrow 1- as

itte
y li
shown, and pull off delivery line in direction of -arrow 2- without
rm
ab
pe
tools and without »jerking«.

ility
ot
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Caution h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Open clip ⇒ Item 6 (page 333) and remove injector for reducing
agent - N474- .
nform
ercia
Installing
m
a
com
– Locate injector for reducing agent - N474- with new sealing

tion in
washer, taking account of lugs on reducing catalytic converter

r
te o
thi
(electrical connector faces upwards).

s
iva
do
r
– Place new securing bolt over connection and push together

rp
cum
fo
until it engages. This action locates the injector for reducing

en
ng
t.
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agent - N474- .
Co
Cop py
ht. rig
– Position bolt and tighten to specified torque
rig ht
py by
Vo
⇒ Item 6 (page 333) .
co lksw
by
cted agen
Prote AG.
– First connect electrical cable followed by delivery line.

4 Exhaust gas temperature regulation

⇒ “4.1 Assembly overview - exhaust gas temperature regulation
”, page 337
⇒ “4.2 Removing and installing parts of exhaust gas temperature
regulation”, page 338
4.1 Assembly overview - exhaust gas tem‐

perature regulation
Caution
The threads of the exhaust temperature senders -G448- , -

G495- and -G648- are coated. DO NOT also grease with high-
temperature paste. It is imperative to tighten to the torque
specified below. Otherwise this can lead to loosening of the
nuts/bolts and subsequent failure.
1 - Turbocharger
2 - Control line, 45 Nm
❑ If not fitted, seal with
dummy plugs.
3 - Particulate filter
4 - 10 Nm
5 - Bracket
❑ Bolted to diesel l wage
ksparticu‐ es n
o ot g
late filter.ed by V ua
ra
is nte
or
6 - Hose auth eo
ra
ss c
7 - Bracket
ce
e
nl
pt
du
❑ For pressure differential

an
itte
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sender - G505- .
erm
ab
ility
ot p
8 - Differential pressure sender

wit
, is n
- G505-
h re
hole

spec
⇒ page 280
es, in part or in w
t to the co
9 - Securing clip
10 - 10 Nm
rrectness of i
11 - 7 Nm
l purpos
12 - Exhaust gas temperature

sender 3 - G495- , 60 Nm
nf
ercia

rm
m
⇒ page 340
atio
om
n in
❑ Thread of sender is
or c
thi
coated.
te
sd
iva
❑ Do not additionally oil or

o
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cu
grease.
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13 - Lambda probe - G39- with Cop py
t. rig
lambda probe heater - Z19- , yri
gh by
ht
50 Nm cop Vo
by lksw
cted agen
❑ Removing and installing ⇒ page 282 Prote AG.
4. Exhaust gas temperature regulation 337

14 - Exhaust gas temperature sender 4 - G648- , 60 Nm

❑ Thread of sender is coated.
❑ Do not additionally oil or grease
15 - Exhaust gas temperature sender 1 - G235- , 45 Nm
❑ Coat with high-temperature paste; High-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
4.2 Removing and installing parts of ex‐

haust gas temperature regulation
⇒ “4.2.1 Removing and installing exhaust gas temperature sender
1 G235 ”, page 338
⇒ “4.2.2 Removing and installing exhaust gas temperature sender
3 G495 ”, page 340 wage
es ks not
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⇒ “4.2.3 Removing and installing exhaust
ed
by gas temperature sender ara
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4 G648 ”, page 342 thoris eo
u ra
sa
4.2.1 Removing and installing exhaust gas
s c
ce
le
un
pt
temperature sender 1 - G235-
an
d
itte
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rm
ab
pe
ility
ot
wit
♦ Tool set, 17 AF - T10395-
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi

s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing

– Release and pull off electrical connectors -Arrow A- and ex‐

pose electric wiring.
– Remove the heat shield by unscrewing the screws -arrow-.

– Unscrew exhaust temperature sender 1 - G235- -item 1- from
exhaust manifold.
Installing
Note
♦ Coat the thread of exhaust gas temperature sender with high-

temperature paste; High-temperature paste ⇒ Electronic
♦ Fit cable ties in the same place when installing.
Installation position of exhaust temperature sender exhaust tem‐

perature sender 1 - G235- :
• Angled shaft must have a distance -a-ge=n A3G…

. Vo5lksmm
wageto
n Abolting
G do
of turbocharger support. Volksw
a es n
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– Electrical connections and risrouting ⇒ Current flow diagrams,
e nte
ho eo
Electrical fault finding aand
ut Fitting locations. ra
ss c
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un
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an
d
itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
Specified torque
rrectness of i

l purpos
Exhaust gas temperature sender 1 - G235- 45 Nm

nform
mercia
a
com
tion in
r
te o
thi
s
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Caution
The threads of the exhaust temperature sender are coated. Do

NOT additionally grease with high-temperature paste and al‐
ways adhere to the prescribed tightening torque ⇒ page 337 .
Otherwise this can lead to loosening of the nuts/bolts and sub‐
sequent failure.

♦ Tool set, 17 AF - T10395-
. Volkswagen AG
gen AG does
♦ Lambda probe open ringVospanner
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set - 3337- not
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, is n
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hole
spec
es, in part or in w
t to the co
Removing
rrectness of i

l purpos
– Remove nuts -arrows-.

nform
ercia
– Remove shield -1-.

m
– Remove Lambda probe - G39- with lambda probe heater -

com
tio
Z19- ⇒ page 282 .

n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

CC
n AG2012 ➤
. Volkswag,en
Golf
AG dCabriolet 2012 ➤
wage oes
4-cylinder diesel engine (2.0 l engine, common Volks rail, generation II) - Edition
not
gu 09.2013
by ara
ed nte
ris
– Release and pull off connector -1-, and uncliputith from the
o eo
ra
bracket. ss
a c
ce
e
nl
– Uncover cables.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
– Unscrew exhaust temperature sender 3 - G495- -item 1-.
sd
iva
o
r
rp
cu
Installing
o
m
f
en
ng
t.
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Install in reverse order. While doing so, note the following: t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
Fit cable ties in the same place when installing.
Installation position of exhaust temperature sender 3 - G495-

-item 1-:
• Angled end to left-hand side of vehicle.
• Angle -α- to marking -arrow- = approx. 17°.
• Specified torque ⇒ page 337 .
– Install Lambda probe - G39- together with lambda probe heat‐
er - Z19- ⇒ page 282 .
Specified torques
Lambda probe - G39- 50 Nm
Heat protection 10 Nm


Caution
Threads of exhaust temperature sender are coated. Do NOT

additionally grease with high-temperature paste and always
adhere to the prescribed tightening torque ⇒ page 337 . Oth‐
erwise this can lead to loosening of the nuts/bolts and subse‐
quent failure.

♦ Tool set, 17 AF - T10395-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
Removing ht. rig
rig ht
py by
o Vo
– Remove noise insulation ⇒ General body repairs, exterior; by c lksw
cted agen
Prote AG.
sulation .

– Disconnect electrical connector -2- for exhaust temperature

sender 4 - G648- and free electrical line.
– Expose cable.
– Remove exhaust temperature sender 4 - G648- -arrow-.

– Remove exhaust temperature sender .
Installing
Note
Fit cable ties in thewsame

agen place when Ainstalling.
AG. Volkswagen G d
oes
ks not
Vol gu
d by ara
– Electrical
oris connections and routing ⇒ Current flow
e ntediagrams,
eo
Electrical
aut
h
fault finding and Fitting locations. ra
ss c
ce
e
nl
Specified torque
pt
du
an
itte
y li
erm

ab
ility
ot p

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5 Exhaust gas recirculation

⇒ “5.1 Assembly overview - exhaust gas recirculation ”,
page 344
⇒ “5.2 Checking changeover for exhaust gas recirculation cooler”,
page 345
⇒ “5.3 Removing and installing exhaust gas recirculation cooler”,
page 345
⇒ “5.4 Checking exhaust gas recirculation cooler for leaks”, page
348
5.1 Assembly overview - exhaust gas recirculation
1 - 9 Nm
pipe
ger of cracking.
3 - 9 Nm
4 - Gasket
❑ Renew.
. Volkswagen AG
gen AG does
5 - Vacuum line olks
wa not
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❑ Do not alter shape.
ris
ed
b ara
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6 - 9 Nm s au ra
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s
❑
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un
pt
an
d
7 - Gasket
itte
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erm
ab
❑ Renew.
ility
ot p
wit

is n
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pipe
ole,
spec

t to the co
ger of cracking.
9 - 9 Nm
rrectne
❑
s
10 - Clamp, 5 Nm
s o
cial p
f i

nform
cooler
mer
atio
m
❑ With integrated exhaust

o
n
c
gas recirculation valve -

i
or
n thi
N18- with exhaust gas

te
sd
va
recirculation potentiom‐
i
o
pr
eter - G212- .
um
r
fo
en
ng
t.
❑ Checking changeover
yi Co
op
⇒ page 345 .
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
❑ Checking exhaust gas recirculation cooler for leaks ⇒ page 348
agen
Prote AG.
12 - 9 Nm
13 - Gasket
❑ Renew.

14 - Gasket
❑ Renew. agen
AG. Volkswagen AG d
oes
olksw not
15 - Exhaust gas recirculationedpipe
by
V gu
ara
is nte
❑ With flexible joint; udo
th not bend flexible joint - danger of cracking. e or
or
a ac
16 - 9 Nm ss
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le
un
pt
17 - 9 Nm
an
d
itte
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erm
ab
18 - Gasket
ility
ot p
❑ Renew.
wit
is n
h re
ole,
spec
5.2 Checking changeover for exhaust gas
t to the co
recirculation cooler
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure
– Remove heat shield sleeve.
– Pull vacuum hose off vacuum unit and connect hand vacuum
pump - VAS 6213- .
– Operate hand vacuum pump to create a vacuum.
• The linkage of the changeover for the exhaust gas recircula‐
tion cooler must move -arrows-.
If linkage does not move or only moves in jerks:
♦ Vacuum actuator is defective.
♦ Changeover flap for exhaust gas recirculation is tight.
Note
Fit heat shield sleeve in the same place when installing.
5.3 Removing and installing exhaust gas re‐

circulation cooler
5. Exhaust gas recirculation 345

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
s c
♦ Hose clip pliers - VAS 6362- s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
If the exhaust gas recirculation cooler is to be removed or re‐

nform
ercia
newed
m
at
– First, in the “selection of functions and components ” of a

om
io
⇒ Vehicle diagnostic tester test pump 2 for coolant circulation

n
c
in t
or
- V178- .
his
ate
do
riv
If coolant circulation pump 2 - V178- is not OK, this may be the

p
cum
or
cause of the faulty exhaust gas recirculation cooler.

f
en
ng
t.
yi Co
Removing Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew bolts for pipes -A- of exhaust gas recirculation and

remove pipes.
– In vehicles with an auxiliary heater, remove the brackets for
the coolant lines leading to the auxiliary heater from the cylin‐
der block or transfer gearbox and the oil sump.
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Place drip tray for workshop crane - VAS 6208- beneath en‐
gine.
– Pinch off coolant hoses -1- and -3- with hose clamps -3094-
and remove from exhaust gas recirculation cooler; loosen
hose clamps for this.
– Remove vacuum hose -4- from vacuum unit and free.
– Unscrew bolts -arrows- and remove exhaust gas recirculation
cooler.
Installing
⇒ “5.1 Assembly overview - exhaust gas recirculation ”,
page 344 .
AG. Volkswagen
Installation is carried out in the reverse
lksw
ageorder;
n
note theAfollowing:
G do
es n
o ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
e
♦ Renew gaskets, seals and self-locking nuts.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
♦ Fit heat shield sleeve in the same place when installing.

t to the co
– Installing support for turbocharger with oil supply line, inlet
connection and pulsation damper ⇒ page 226 .
rrectness of i

l purpos
– Install particulate filter ⇒ page 311 .

nf
ercia

orm
m
atio
om
5.4 Checking exhaust gas recirculation

n in
or c
thi
cooler for leaks

te
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi Co
♦ Cooling system tester - V.A.G 1274 B- ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

wage es n
yV
olks CC 2012 ➤ , Golf Cabrioletot g 2012 ➤
b ua
ir se common rail, generation II) - Edition a09.2013
d r n
tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hose clip pliers, e. g. hose clip pliers - V.A.G 1921-
♦ Adapter hose 1.5 m x 16 mm in diameter

Test prerequisite
• Engine at operating temperature.
Test sequence:
– Observe safety instructions ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 6 .
sulation .
– Checking cooling system for leaks ⇒ page 187 .
• If leaks are found, rectify them.

Golf convertible
– Release connector -1-, and pull it off pressure differential
sender .
– Remove bolt -2-.
– Push bracket -3- for pressure differential sender out of guide
in direction of -arrow-.
– Lay bracket -3- to one side. Lines wremain
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– Unclip fuel lines -2- from retainer -3-.
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– Open plug-in connectors -A- and -B- of fuel lines, and pull off
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fuel lines. Disconnect plug-in connectors ⇒ Fuel supply – die‐
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– Lay supplementary fuel pump - V393- or fuel pump 2 - V277-
-1- to one side. Lines remain connected.

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– Open plug-in connectors -A- and -B- of fuel lines, and pull off
fuel lines. Disconnect plug-in connectors ⇒ Fuel supply – die‐
sel engines; Rep. gr. 20 ; Disconnecting plug-in connectors .
WARNING

ries and skin contact. Before loosening hose connections,
– Unclip fuel lines, and move them clear.

– Lay fuel lines to one side.
– Release and disconnect connector -3- from pressure differen‐

tial sender -4-.
– Unclip hoses -2- from retainer.
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– Clamp off coolant hose -1- on coolant circulation pump 2 -

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Cover filler cap on expansion tank with a cloth and open care‐

– Open clips -arrow-.

– Pull coolant hose -2- off coolant pipe -1-
⇒ Item 24 (page 211) .
– Open coolant expansion tank.
– Hold the hose which has been pulled off into a suitable con‐
tainer.
– Carefully open hose clamp, up to 25 mm in diameter - 3094- ,
and drain coolant until the coolant expansion tank is empty
⇒ page 189 .
– Connect adapter hose -2- to coolant pipe -1-.

– Secure adapter hose -2- with a hose clip -arrow-.
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– Release and disconnect connector -1- from coolant expansion s
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– Remove bolts -3- and remove coolant expansion tank -2-.

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– Clamp off hose -2- with hose clamps, up to 25 mm in diameter

- 3094- .
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– Open clip -arrow-, and pull off water hose -3-.

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– Connect adapter hose -3- to the free connection on coolant

expansion tank -1-.
– Secure adapter hose -3- with a hose clip.
– Place coolant expansion tank -1- onto fuel filter -2-.

– Fill coolant up to -min.- mark ⇒ Rep. gr. 19 ; Cooling system/
coolant; Draining and filling coolant .
– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for ocooling
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– Join connection piece - V.A.G 1274 d bB/1- to cooling system
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– Using hand pump on cooling system tester - V.A.G 1274 B- ,

build up a pressure of 1.5 bar.
• The pressure must not drop by more than 0.2 bar within 10 mi‐
nutes.
If pressure drops by more than 0.2 bar:
– Check hose clamps, up to 25 mm in diameter - 3094- for firm
seating, and retighten them if necessary.
– Repeat pressure loss test ⇒ page 353 .
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– The exhaust gas recirculation cooler has d by V a leak. Renew ex‐ gu
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haust gas recirculation cooler ⇒ pageorise 345 . nte
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The exhaust gas recirculation cooler does not have a leak.
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– Install all water hoses, and secure them with hose clips
rm
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⇒ page 186 .
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DANGER!
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Risk of scalding! Before disconnecting cooling system tester -
V.A.G 1274 B- from the connecting hose or connector - V.A.G
rrectness of i
1274 B/1- , it is essential that the pressure is relieved. To do
this, press pressure relief valve on cooling system tester -
l purpos
V.A.G 1274 B- until pressure gauge displays value of »0«.
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Specified torques
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♦ ⇒ “3.1 Assembly overview - coolant pipes ”, page 210
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♦ ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 221

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♦ ⇒ “1.1 Coolant hose schematic diagram”, page 186

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♦ ⇒ “3 engine cover panel”, page 41
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♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Assembly overview - noise insulation .

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⇒ “1.1 Removing and installing glow plugs”, page 355
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⇒ “1.2 Removing and installing automatic glow period control
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⇒ “1.4 Removing and installing engine speed sender”,
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page 358
1.1 Removing and installing glow plugs
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♦ Jointed wrench 10 mm - 3220-
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♦ Pliers - 3314-
Removing
Caution
♦ Make sure that no wiring connections are damaged when

disconnecting the glow pin plug connectors. Otherwise the
whole wiring harness will need to be renewed.
♦ Do not compress the pliers - 3314- too firmly to separate
the glow pin plug connectors, otherwise the support
sleeve may be damaged.
1. Glow plug system 355

– Open retaining clips -arrows- of wiring harness.
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– Position pliers - 3314- with groove -arrow A- on support sleeve
h re
shoulder -arrow B-.
hole
spec
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– Pull connectors off glow pin plugs.
t to the co
– Clean glow pin plug opening in cylinder head.
• Make sure that no dirt falls into the cylinder.
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Note
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♦ Cleaning procedure:
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♦ Use a vacuum cleaner to remove coarse dirt.
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his
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plug opening, let it work in briefly, and blow out with com‐
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– Use U/J extension and 10 AF socket - 3220- to release glow
AG.
pin plugs.
Installing
– Reattach glow pin plug connectors -1- to glow pin plugs

-arrow-.
Note
Make sure that glow plug connectors are firmly seated.
356 Rep. gr.28 - Glow plug system

Specified torque
Glow plugs 18 Nm
1.2 Removing and installing automatic glow

period control unit
Removing
– Unscrew bolts -arrows- and take out battery support.
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– Pull out relay holder under E-box in engine compartment
, is n
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-arrow-.
hole
– Pull automatic glow period control unit - J179- -Item 1- out of spec
es, in part or in w
its slot in the relay holder under the E-box in the engine com‐ t to the co
partment.
Installing
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– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐

moving and installing battery .
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1.3 Removing and installing Hall sender

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Fitting location ⇒ Item 3 (page 89)

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– Release and disconnect connector -1- from Hall sender -

G40- .
– Unclip connector on the water pipe.
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– Screw off Hall sender - G40- -arrow-. yV
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– Remove webs and repair aperture cover -arrows- with a
rrectne
screwdriver.
– Remove Hall sender - G40- from cylinder head and insert its
ss
connector through repair hole in toothed belt guard.
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Installing
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♦ Seal repair aperture in toothed belt guard with rubber plugs as

thi
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specified in ⇒ Electronic Parts Catalogue (ETKA) .

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Specified torque p by
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Hall sender - G40- on the cylinder head 10 Nm
1.4 Removing and installing engine speed

sender

♦ 4 AF socket - T10370-
Removing
Fitting location ⇒ Item 5 (page 66) agen
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Rep. gr. 66 ; Noise insulation;
oris Assembly overview - noise in‐
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– Clamp off coolant hoses from the engine oil cooler with the
ce
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un
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hose clips up to 25 mm - 3094- .

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– Undo the spring clips using -arrow-with the spring clip pliers -
ab
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Collect escaping coolant with drip tray - VAS 6208- .

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– Pull coolant hoses off engine oil cooler.

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– Remove oil filter bracket with engine oil cooler ⇒ page 169
– Release and pull off connector on engine with assembly tool

nform
ercia
- T10118- .
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– Loosen securing bolt -arrow- with socket AF 4 mm - T10370-

and remove speed sender.
Installing
Install in reverse order. While doing so, note the following: lkswage es n
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– Install oil filter bracket with engine oil cooler. ir se
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– Replenish coolant ⇒ page 189 . au ac
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Specified torques hole
spec
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t to the co
Engine speed sender - G28- 5 Nm
Oil filter bracket ⇒ “3.2 Removing and installing oil filter housing”, page 169
rrectness of i
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4-Cylinder Diesel Engine (2 0 L Engine Common Rail Generation II)

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4-Cylinder Diesel Engine (2 0 L Engine Common Rail Generation II)

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Service d by

Golf Cabriolet 2012 ➤

4-cylinder diesel engine (2.0 l engine, common rail,

CFH CFFB CFG CLLA CFFA CFG

Service Department. Technical Information

All rights reserved.

Copyright © 2013 Volkswagen AG, Wolfsburg D3E8043AD3C

00 - Technical data . . . . . . . . . . . . . . . . .wa.g.en. A.G.. V.o.lk.sw.a.ge.n.AG. d. o.e . . . . . . . . . . . . . . . . . . . . 1

2.5 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.5 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

2.1 Assembly overview - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.1 Assembly overview - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4.2 Removing and installing balance shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2.4 Electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

1.2 Filling, bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

1.3 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

2 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

2.5 Removing and installing high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . 260

9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1.3 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

1.4 Removing and installing engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

1.1 Engine number/engine data

1.1.1 Engine number

meric). The first part (maximum 4 characters) makes up the

“engine code”, and the second part (6 characters), the “serial

Golf Cabrio 2011 ► 11.11 ►

Emissions fulfil EU 5 plus EU 5 EU 4

Capacity l 2.0 2.0 2.0 2.0 2.0 2.0

Output kW at rpm 103/4,000 100/4,200 103/4,200 125/4,200 130/4,200 125/4,200

1) Particulate reduction system instead of particulate filter

2 Rep. gr.00 - Technical data

2 Safety instructions agen

⇒ “2.3 Safety precautions when working on vehicles with a Start/

⇒ “2.4 Safety precautions when working on cooling system”, page

⇒ “2.5 Safety precautions when working on the SCR system”,

The fuel line is under pressure.

Risk of injury to eyes and skin from fuel.

Wear eye protection and protective clothing to avoid eye inju‐

ries and skin contact. Before loosening hose connections,

carefully opening the connection point.

♦ Always switch off the ignition before connecting or discon‐

♦ Observe required procedures when disconnecting battery